Issue link: https://industrialengineer.epubxp.com/i/826827
36 ISE Magazine | www.iise.org/ISEmagazine Do it right the first time determine Six Sigma tolerances or confirm that customer expectations are met. Benefits By understanding the voice of the customer from the onset and using it throughout the product development process, or- ganizations can reduce costs significantly. When changes to a product design are made early in product development, the costs are relatively low. However, the cost to make changes in the product design increases significantly over time as the product moves from research through design, prototype and production – particularly if defective or unsatisfactory prod- ucts reach customers. For example, once the design moves to the prototype FIGURE 1 A better design methodology Design for Six Sigma has a number of tools available to the practitioner during its five-phase methodology. Phase Phase description Tools used Define • Define customers (internal and external). • Define customer requirements. • Gather needs. • Identify the business case for the project. • Create project charter. • Develop project plan. • Form the team. • Translate needs to critical to satisfaction (CTS). • Translate CTSs to functional requirements. • Assess technology. • Develop plan. • Assess risk. • Project charter • Responsibilities matrix • Communication plan • Team ground rules • Voice of the customer • Stakeholder analysis • Data collection plan • Survey design • Quality function deployment • Project plan • Kano model • Product technology roadmap • Balanced scorecard • Measurement systems analysis Measure • Translate customer requirements into engineering requirements. • Translate functional requirements to design parameters. • Develop and evaluate design alternatives. • Resolve design conflicts. • Flow down system design to subsystems. • Design for reliability and maintainability. • Mistake proofing • Assess risk. • Benchmarking • Voice of the customer • Operational definitions • Quality function deployment • Pugh concept selection matrix • TRIZ • Design scorecard • Design failure modes and effects analysis (FMEA) • Axiomatic design • Standardization Analyze • Develop transfer functions. • Develop system capabilities. • Generate concepts. • Evaluate concepts. • Assess design gaps. • Select concept. • Assess risk. • Brainstorming • Quality function deployment • Design of experiments • TRIZ • Pugh concept selection matrix • Design scorecard • Process verification • Design failure mode and effects analysis (FMEA) • Process failure mode and effects analysis • Reliability testing • Measurement systems analysis Design • Optimize the product or process design for robustness. • Optimize tolerances. • Demonstrate process and product capability. • Mistake proof the design. • Assess risk. • Brainstorming • Design failure mode and effects analysis (FMEA) • Poke-yoke • Design of experiments • Parameter design • Tolerance design • Design for X • Capability analysis Verify • Verify product performance. • Verify process performance. • Monitor system capability. • Implement design and process control plans. • Develop transition plans. • Statistical process control • Control plan • Cost analysis • Process capability • Sigma level