Preface ix Acknowledgments xvii About the Authors xix Section I Getting Started 1 Chapter 1 What Is Design for Six Sigma? 3 Design for Six Sigma Defined 3
The Risk of Development 4
A Little History 5
An Overview of the Methodology 7
Chapter 2 The Business Case for DFSS 11 The Product Life Cycle 11
Where Have All the Vacuum Tubes Gone? 13
Understanding Dynamic Markets: The Kano Model 15
The Role of DFSS 18
Chapter 3 Six Sigma Financial Metrics 21 Candy Wrapper Film: A DFSS Case Study 21
How to Measure Success in a DFSS Project 22
The Cost of Long-Term Variation 33
Chapter 4 Project Identification and Portfolio Management 41 Linking Projects to Strategy 41
The Project Charter 42
DFSS Projects Linked to Financial Results 43
Project Hopper and Pipeline Management 46
Managing the Commercialization Pipeline 48
Technology Platform Projects 48
Project Pipeline Scorecard 48
Chapter 5 Stage-Gate Processes 51 The Stage-Gate Structure 51
Stage-Gate 1: Opportunity Assessment 53
Stage-Gate 2: Market Analysis and Product Definition 55
Stage-Gate 3: New Product Concept Finalized 55
Stage-Gate 4: Design of the New Product and Supporting Manufacturing Process 58
Stage-Gate 5: Validate Product and Process Design 58
Stage-Gate 6: Product Launch Plan 60
Managing the Stage-Gate Process 62
Chapter 6 Project Management 67 DFSS Project Roadmaps 67
Developing the Project Schedule 69
Project Schedule Management 73
Good Project Management 74
Section II Preparing the Business Plan 75 Chapter 7 Business Plan Overview 77 Review of the Business Plan at Gate 3 77
Components of the Business Plan 77
Chapter 8 Market Segmentation 83 The Financial Value of Market Segmentation 83
Developing the Segmentation Strategy 89
Chapter 9 Identifying Market Opportunities 93 The SWOT Analysis 93
Developing the Ratings by Market Segment 95
SWOT Analysis Results 97
The Market FMEA 98
Chapter 10 Defining Product Value 101 The Value Concept 101
Making Quality a Weapon 102
Mapping the Value Chain 105
Tools for Defining Value 107
Chapter 11 Estimating Financial Value 109 Calculating the Project Value 109
How to Handle Fixed Costs 110
Examining the Project Returns 115
Chapter 12 Product Positioning 123 The Market Perceived Quality Profile 123
Product Positioning Maps 129
Section III The Voice of the Customer 131 Chapter 13 Concept Development 133 The Concept Development Process 133
Concept Development Applications 135
Advantages of the Concept Development Process 135
Chapter 14 Developing the Interview Guide 139 Developing a Purpose Statement 139
Identifying and Listing Five to Ten Bullet-Point Interview Objectives 140
Developing a Customer Selection Matrix 141
Creating the Interview Guide Questions 143
Chapter 15 Conducting Customer Interviews 151 Preparing for the Interviews 151
Interview Team Roles 152
Conducting the Interview 153
Debriefing the Interview 155
Good Project Management of the Interview Process 155
Practice, Practice, Practice 156
Chapter 16 KJ Analysis 157 An Overview of the KJ Process 158
The Image KJ 158
The Requirements KJ 168
The Next Steps 178
Chapter 17 Relative Importance Survey 179 Designing and Conducting the Survey 179
Analyzing the Survey Results 183
Identifying Requirements in Kano Terms 185
Chapter 18 Ideation 187 The Ideation Process 187
Ideation in the Candy Wrapper Film Case Study 190
Chapter 19 Pugh Concept Selection 193 The Pugh Concept Selection Process 194
Pugh Concept Selection in the Candy Wrapper Film Case Study 198
Chapter 20 QFD 199 The Value of QFD 199
Executing the QFD 201
The QFD Flowdown 206
QFD across the Value Chain 209
Some Final Thoughts 215
Chapter 21 TRIZ 217 Technical Contradictions 218
The TRIZ Methodology 218
Some Final Thoughts on TRIZ 229
Chapter 22 Critical Parameter Management 231 Documenting Critical Information from the QFD 232
The Critical Parameter Scorecard 232
The Benefits of Using Critical Parameter Scorecards 236
Section IV Product/Process Development 239 Chapter 23 Process Mapping 241 Types and Uses of Process Maps 241
The Process Variables Map 241
The "As-Is/Can-Be" Process Map 247
Some Final Thoughts on Process Mapping 249
Chapter 24 Cause and Effects Matrix 251 Comparing C&E Matrix and QFD3 251
Developing the C&E Matrix 252
Using the C&E Matrix Output 257
Chapter 25 Failure Modes and Effects Analysis 263 Two Types of FMEA in New Product Development 263
The Design FMEA 264
The Process Design FMEA and the Process Manufacturing FMEA 271
Chapter 26 Statistical Analysis Tools Overview 275 Variation in Product and Process Development 275
Some Basic Statistics 279
Graphical Analysis Techniques 282
Numerical Descriptive Statistics 301
A Look Ahead 303
Chapter 27 Measurement Systems Analysis 307 Measurement System Error 307
The Impact of Measurement Error in Development 308
Assessing Measurement System Usefulness 309
Conducting a Measurement System Study 316
Long-Term Measurement System Assessments 322
Chapter 28 Process Capability 323 Using the Normal Distribution Curve to Estimate Waste 323
Short-Term Process Capability Analysis 325
Long-Term Process Variation: The Shift 326
Designing for Six Sigma Performance 329
Revisiting the Cp Statistic 330
The Cpk Statistic 332
Long-Term Process Capability Analysis 335
Interpreting the Capability Indices 336
Capability Analysis in Minitab 337
Ensuring Measurement System Adequacy 341
Process Capability for Attribute Data 343
The Importance of Process Capability 344
Chapter 29 Tools for Data Analysis 347 General Methods of Data Analysis 347
Hypothesis Testing 348
Sample Size Calculation 350
Comparing a Process Mean to a Target Value 352
Comparing Means and Standard Deviations from Two Film Samples 359
Comparing Two Variances 364
Comparing Two Means: 2-Sample t-test 364
Comparing 2 Medians: The Mann-Whitney Test 367
Comparing Two Means: Paired Comparisons 367
Assessing Means and Standard Deviations: Con*dence Interval 371
Comparing Means and Standard Deviations from More Than Two Samples 374
Comparing Variance 377
Comparing Means: One-Way ANOVA 379
Comparing Medians: Kruskal-Wallis Test 384
Data Comparison Tools Summary 385
Correlation Analysis 385
Regression Analysis for a Single Input Variable 388
Multiple Regression Analysis 394
Correlation and Regression Analysis Summary 400
References 400
Chapter 30 Design of Experiments 401 Full Factorial Designs 401
Fractional Factorial Designs 415
Response Surface Designs 424
Choosing an Experimental Design 430
References 432
Chapter 31 Robust Design 433 Quantifying Robust Design Performance 433
The Taguchi Approach to Robust Design 435
Robust Design Example 438
Alternative Approaches to Robust Design 442
Dealing with Variation 447
Chapter 32 Mixture Experiments 449 Mixture Equations 449
Mixture Designs 451
Creating Mixture Designs in Minitab 451
Analyzing a Mixture Design Experiment 455
Response Surface Study for a Mixture Investigation 458
Choosing a Mixture Design 466
References 468
Chapter 33 Seeking an Optimal Solution 469 The Multiple Response Optimization Process 470
Three-Response Optimization 477
Monte Carlo Simulation in Optimization 481
Multiple Response Optimization Final Thoughts 488
Chapter 34 Design for Reliability 491 A Roadmap for Reliability 491
Design for Reliability 493
Identifying Reliability Requirements: VOC 493
Reliability Expectations and the Kano Model 494
Customer Reliability Expectations 495
Typical Reliability Metrics 495
The Hazard Function 498
Types of Reliability Tests 503
Reliability and Failure Modes and Effects Analysis 506
Reliability Functions and Mathematical Models 508
Types of Distributions and the Hazard Function 511
Reliability Modeling Using Minitab Software 512
The Implications of Product Reliability on Warranty Costs 516
Chapter 35 Statistical Tolerancing 519 Worst Case Analysis 520
Root Sum of Squares Analysis 521
Six Sigma Tolerance Analysis 525
Chapter 36 Production Scale-up 541 Confirming the Product 542
Design for Manufacturability Assessment 550
Scaling up the Product 553
Chapter 37 Control Plans 559 Developing a Control Plan 560
The Final Control Plan Package 572
Section V Product Launch and Project Post-Mortem Analysis 575 Chapter 38 Product Launch and Project Post-Mortem Analysis 577 Product Launch Planning 577
Project Post-Mortem Analysis 583
Conclusions 588
Appendix A Glossary 589 Appendix B Abbreviations 599 Index 601 