1. DESIGN FOR SIX SIGMA INTRODUCTION
- What is Six Sigma
- Design for Six Sigma Objectives and Role in Product Development
- Design for Six Sigma Framework – Identify, Design, Optimize and Validate (IDOV)
2. IDENTIFY PHASE
- Identify Customer Needs – Voice of the Customer (VOC) Process
- Derive Product Requirements – Quality Function Deployment (QFD)
- Identify Technical Requirements with Critical to Quality (CTQ) Variables and Specification Limits
3. DESIGN PHASE
- Develop a Manufacturable Design with Design for Manufacturability/Assembly (DFM/A)
- Simplify and Standardize
- Design for Part Handling, Orientation, Ease of Location and Insertion, and Joining/Fastening
- Design within Process Capabilities
- Developing and Applying Design Guidelines
- Identify and Counter Potential Risks Using Failure Modes and Effects Analysis (FMEA)
- Types of FMEAs
- Basic FMEA Procedure
- Taking Corrective Actions
- Control Plans
- Managing an FMEA
- Regulations & Standards
- Mistake-Proof Design
- The Six Principles of Mistake-Proofing
- Identifying Mistake Opportunities and Developing Mistake-Proofing Approaches
4. OPTIMIZE PHASE
- Assess Process Capabilities To Achieve Critical Design Parameters and Meet CTQ Limits
- Optimize Design and Reduce Variability – Variation Reduction and Robustness
- Robust Tolerance Analysis
- Capability Studies (Cp, Cpk, 6s)
- Understanding The Results
- Design of Experiments (DOE)
- Three Approaches to Robustness
- Tolerance Analysis – Worst-Case Tolerances, Statistical Tolerances & Process Tolerances
5. VALIDATE PHASE
- Assess Risks and Plan Test and Validation
- Identify Key Inputs and Establish Control Plan for Key Inputs
- Product Validation – Determine Worst Case Conditions and Perform Worst Case Testing
- Perform Process Validation
- Verify Capability of Critical to Quality Characteristics