Six Sigma and Beyond: Design for Six Sigma, Volume VI

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ISBN: 9781574443158 | 1574443151
Cover: Hardcover
Copyright: 11/13/2002

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This volume addresses design improvement from the perspective of prevention by introducing readers to the tools of the Six Sigma design process. The author discusses the issues of designing for Six Sigma, covering the topics that any Shogun Six Sigma Master must be familiar with: customer satisfaction, quality function deployment, benchmarking, systems engineering, value engineering, reliability and maintainability, design for manufact'urability, mistake proofing, failure mode and effect analysis, project management, and financial concepts.

Introduction Understanding the Six Sigma Philosophy

(1)

A Static versus a Dynamic Process

(1)

Products with Multiple Characteristics

(2)

Short- and Long-Term Six Sigma Capability

(1)

Design for Six Sigma and the Six Sigma Philosophy

(2)

Design Phase

(1)

Internal Manufacturing

(1)

External Manufacturing

(1)

References

(2)

Prerequisites to Design for Six Sigma (DFSS)

(40)

Partnering

(16)

The Principles of Partnering

(1)

View of Buyer/Supplier Relationship: A Paradigm Shift

(1)

Characteristics of Expanded Partnering

(2)

Evaluating Suppliers and Selecting Supplier Partners

(1)

Implementing Partnering

(1)

Establish Top Management Enrollment (Role of Top Management --- Leadership)

(1)

Establish Internal Organization

(1)

Option 1: Supplier Partnering Manager

(1)

Option 2: Supplier Council/Team

(1)

Option 3: Commodity Management Organization

(1)

Establish Supplier Involvement

(1)

Establish Responsibility for Implementation

(2)

Reevaluate the Partnering Process

(1)

Ratings

(2)

Terms Used in Specific Questions

(1)

Major Issues with Supplier Partnering Relationships

(1)

How Can We Improve?

(1)

Basic Partnering Checklist

(1)

Leadership

(1)

Information and Analysis

(1)

Strategic Quality Planning

(1)

Human Resource Development and Management

(1)

Management of Process Quality

(1)

Quality and Operational Results

(1)

Customer Focus and Satisfaction

(1)

Expanded Partnering Checklist

(1)

Leadership

(1)

Information and Analysis

(1)

Strategic Quality Planning

(1)

Human Resource Development and Management

(1)

Management of Process Quality

(1)

Quality and Operational Results

(1)

Customer Focus and Satisfaction

(1)

The Robust Team: A Quality Engineering Approach

(9)

Team Systems

(1)

Input

(1)

Signal

(1)

The System

(1)

Output/Response

(1)

The Environment

(1)

External Variation

(1)

Internal Variation

(1)

The Boundary

(1)

Controlling a Team Process: Conformance in Teams

(1)

Strategies for Dealing with Variation

(1)

Controlling or Eliminating Variation

(1)

Compensating for Variation

(1)

System Feedback

(1)

Minimizing the Effect of Variation

(2)

Monitoring Team Performance

(1)

System Interrelationships

(1)

Systems Engineering

(6)

``Systems'' Defined

(1)

Implications of the Systems Concept for the Manager

(2)

Defining Systems Engineering

(1)

Pre-Feasibility Analysis

(1)

Requirement Analysis

(1)

Design Synthesis

(1)

Verification

(1)

Advanced Quality Planning

(7)

When Do We Use AQP?

(1)

What Is the Difference between AQP and APQP?

(1)

How Do We Make AQP Work?

(1)

Are There Pitfalls in Planning?

(1)

Do We Really Need Another Qualitative Tool to Gauge Quality?

(1)

How Do We Use the Qualitative Methodology in an AQP Setting?

(1)

APQP Initiative and Relationship to DFSS

(2)

References

(1)

Selected Bibliography

(2)

Customer Understanding

(48)

The Concept of Function

(16)

Understanding Customer Wants and Needs

(1)

Creating a Function Diagram

(1)

The Product Flow Diagram and the Concept of Functives

(5)

The Process Flow Diagram

(3)

Using Function Concepts with Productivity and Quality Methodologies

(4)

Kano Model

(3)

Basic Quality

(1)

Performance Quality

(1)

Excitement Quality

(2)

Quality Function Deployment (QFD)

(17)

Terms Associated with QFD

(1)

Benefits of QFD

(2)

Issues with Traditional QFD

(1)

Process Overview

(1)

Developing a ``QFD'' Project Plan

(1)

The Customer Axis

(2)

Technical Axis

(1)

Internal Standards and Tests

(1)

The QFD Approach

(1)

QFD Methodology

(4)

QFD and Planning

(2)

Product Development Process

(2)

Conjoint Analysis

(7)

What Is Conjoint Analysis?

(1)

A Hypothetical Example of Conjoint Analysis

(1)

An Empirical Example

(5)

The Managerial Uses of Conjoint Analysis

(1)

References

(1)

Selected Bibliography

(2)

Benchmarking

(72)

General Introduction to Benchmarking

(2)

A Brief History of Benchmarking

(1)

Potential Areas of Application of Benchmarking

(2)

Benchmarking and Business Strategy Development

(3)

Least Cost and Differentiation

(1)

Characteristics of a Least Cost Strategy

100

(1)

Characteristics of a Differentiated Strategy

101

(1)

Benchmarking and Strategic Quality Management

102

(17)

Benchmarking and Six Sigma

105

(2)

National Quality Award Winners and Benchmarking

107

(1)

Example --- Cadillac

107

(1)

A Second Example --- Xerox

108

(1)

Third Example --- IBM Rochester

109

(1)

Fourth Example --- Motorola

110

(1)

Benchmarking and the Deming Management Method

110

(1)

Benchmarking and the Shewhart Cycle or Deming Wheel

111

(1)

Plan

111

(1)

111

(1)

Study --- Observe the Effects

111

(1)

Act

111

(1)

Why Do People Buy?

111

(1)

Alternative Definitions of Quality

112

(5)

Determining the Customer's Perception of Quality

117

(2)

Quality, Pricing and Return on Investment (ROI) --- The PIMS Results

119

(1)

Benchmarking as a Management Tool

119

(7)

What Benchmarking Is and Is Not

120

(1)

The Benchmarking Process

121

(1)

Types of Benchmarking

122

(1)

Organization for Benchmarking

123

(1)

Requirements for Success

124

(2)

Benchmarking and Change Management

126

(3)

Structural Pressure

128

(1)

Aspiration for Excellence

128

(1)

Force Field Analysis

128

(1)

Identification of Benchmarking Alternatives

129

(6)

Externally Identified Benchmarking Candidates

129

(1)

Industry Analysis and Critical Success Factors

129

(1)

PIMS Par Report

130

(1)

Financial Comparison

130

(1)

Competitive Evaluations

131

(1)

Focus Groups

131

(1)

Importance/Performance Analysis

131

(1)

Internally Identified Benchmarking Candidates --- Internal Assessment Surveys

132

(1)

Nominal Group Process: General Areas in Greatest Need of Improvement

132

(1)

Pareto Analysis

132

(1)

Statistical Process Control

133

(1)

Trend Charting

133

(1)

Product and Company Life Cycle Position

133

(1)

Failure Mode and Effect Analysis

134

(1)

Cost/Time Analysis

134

(1)

Need to Identify Underlying Causes

134

(1)

Problem, Causes, Solutions

134

(1)

The Five Whys

134

(1)

Cause and Effect Diagram

134

(1)

Business Assessment --- Strengths and Weaknesses

135

(4)

Prioritization of Benchmarking Alternatives --- Prioritization Process

139

(3)

Prioritization Matrix

139

(1)

Quality Function Deployment (House of Quality)

140

(1)

Importance/Feasibility Matrix

141

(1)

Paired Comparisons

141

(1)

Improvement Potential

141

(1)

Prioritization Factors

141

(1)

Are There Any Other Problems? What Is the Relative Importance of Each of These?

142

(1)

Identification of Benchmarking Sources

142

(7)

Types of Benchmark Sources

142

(1)

Internal Best Performers

143

(1)

Competitive Best Performers

143

(1)

Best of Class

143

(1)

Selection Criteria

144

(1)

Sources of Competitive Information

144

(4)

Gaining the Cooperation of the Benchmark Partner

148

(1)

Making the Contact

149

(1)

Benchmarking --- Performance and Process Analysis

149

(9)

Preparation of the Benchmarking Proposal

149

(1)

Activity before the Visit

149

(1)

Understanding Your Own Operations

149

(1)

Activity Analysis

150

(1)

Define the Activity

150

(1)

Determine the Triggering Event

150

(1)

Define the Activity

150

(1)

Determine the Resource Requirements

151

(1)

Determine the Activity Drivers

151

(1)

Determine the Output of the Activity

151

(1)

Determine the Activity Performance Measure

151

(1)

Model the Activity

152

(1)

Examples of Modeling

152

(1)

Flow Chart the Process

153

(2)

Activities during the Visit

155

(1)

Understand the Benchmark Partner's Activities

155

(1)

Identification of All of the Factors Required for Success

155

(1)

Activities after the Visit

156

(1)

Functional Analysis

156

(1)

Cost Analysis

156

(1)

Technology Forecasting

156

(1)

Financial Benchmarking

157

(1)

Sales Promotion and Advertising

157

(1)

Warehouse Operations

157

(1)

PIMS Analysis

157

(1)

Purchasing Performance Benchmarks

157

(1)

Motorola Example

158

(1)

Gap Analysis

158

(1)

Definition of Gap Analysis

158

(1)

Current versus Future Gap

158

(1)

Goal Setting

159

(2)

Goal Definition

159

(1)

Goal Characteristics

159

(1)

Result versus Effort Goals

159

(1)

Goal Setting Philosophy

159

(1)

Best of the Best versus Optimization

159

(1)

Kaizen versus Breakthrough Strategies

160

(1)

Guiding Principle Implications

160

(1)

Goal Structure

160

(1)

Cascading Goal Structure

160

(1)

Interdepartmental Goals

161

(1)

Action Plan Identification and Implementation

161

(2)

A Creative Planning Process

162

(1)

Action Plan Prioritization

162

(1)

Action Plan Documentation

162

(1)

Monitoring and Control

162

(1)

Financial Analysis of Benchmarking Alternatives

163

(1)

Managing Benchmarking for Performance

164

(2)

References

166

(1)

Selected Bibliography

167

(2)

Simulation

169

(18)

What Is Simulation?

169

(1)

Simulated Sampling

170

(5)

Finite Element Analysis (FEA)

175

(7)

Types of Finite Elements

175

(1)

Types of Analyses

176

(2)

Procedures Involved in FEA

178

(1)

Steps in Analysis Procedure

178

(1)

Overview of Finite Element Analysis --- Solution Procedure

179

(1)

Input to the Finite Element Model

180

(1)

Outputs from the Finite Element Analysis

180

(1)

Analysis of Redesigns of Refined Model

181

(1)

Summary --- Finite Element Technique: A Design Tool

182

(1)

Excel's Solver

182

(1)

Design Optimization

182

(3)

How To Do Design Optimization

184

(1)

Understanding the Optimization Algorithm

184

(1)

Conversion to an Unconstrained Problem

185

(1)

Simulation and DFSS

185

(1)

References

186

(1)

Selected Bibliography

186

(1)

Design for Manufacturability/Assembly (DFM/DFA or DFMA)

187

(36)

Business Expectations and the Impact from a Successful DFM/DFA

189

(3)

The Essential Elements for Successful DFM/DFA

192

(6)

The Product Plan

194

(1)

Product Design

194

(1)

Criteria for Decision between Crash Program and Perfect Product

195

(1)

Case #1 --- Crash Program

195

(1)

Case #2 --- Perfect Product Design

196

(1)

The Product Plan --- Product Design Itself

196

(2)

Define Product Performance Requirement

198

(1)

Available Tools and Methods for DFMA

198

(6)

Cookbooks for DFM/DFA

199

(1)

Use of the Human Body

199

(1)

Arrangement of the Work Place

200

(1)

Design of Tools and Equipment

200

(1)

Mitsubishi Method

200

(2)

U-Mass Method

202

(1)

MIL-HDBK-727

203

(1)

Fundamental Design Guidance

204

(2)

The Manufacturing Process

206

(2)

Mistake Proofing

208

(11)

Definition

208

(1)

The Strategy

208

(1)

Defects

209

(1)

Mistake Proof System Is a Technique for Avoiding Errors in the Workplace

210

(1)

Types of Human Mistakes

210

(1)

Forgetfulness

210

(1)

Mistakes of Misunderstanding

210

(1)

Identification Mistakes

210

(1)

Amateur Errors

211

(1)

Willful Mistakes

211

(1)

Inadvertent Mistakes

211

(1)

Slowness Mistakes

211

(1)

Lack of Standards Mistakes

211

(1)

Surprise Mistakes

211

(1)

Intentional Mistakes

212

(1)

Defects and Errors

212

(1)

Mistake Types and Accompanying Causes

213

(2)

Signals that Alert

215

(1)

Approaches to Mistake Proofing

215

(1)

Major Inspection Techniques

216

(1)

Mistake Proof System Devices

216

(1)

Devices Used as ``Detectors of Mistakes''

217

(1)

Devices Used as ``Preventers of Mistakes''

217

(1)

Equation for Success

218

(1)

Typical Error Proofing Devices

219

(1)

References

219

(1)

Selected Bibliography

219

(4)

Failure Mode and Effect Analysis (FMEA)

223

(64)

Definition of FMEA

224

(1)

Types of FMEAs

224

(1)

Is FMEA Needed?

225

(1)

Benefits of FMEA

226

(1)

FMEA History

226

(1)

Initiation of the FMEA

227

(1)

Getting Started

228

(7)

Understand Your Customers and Their Needs

228

(2)

Know the Function

230

(1)

Understand the Concept of Priority

230

(1)

Develop and Evaluate Conceptual Designs/Processes Based on Customer Needs and Business Strategy

230

(1)

Be Committed to Continual Improvement

231

(1)

Create an Effective FMEA Team

231

(3)

Define the FMEA Project and Scope

234

(1)

The FMEA Form

235

(18)

Developing the Function

238

(1)

Organizing Product Functions

239

(1)

Failure Mode Analysis

240

(1)

Understanding Failure Mode

240

(1)

Failure Mode Questions

240

(2)

Determining Potential Failure Modes

242

(1)

Failure Mode Effects

243

(1)

Effects and Severity Rating

244

(1)

Severity Rating (Seriousness of the Effect)

245

(1)

Failure Cause and Occurrence

246

(1)

Popular Ways (Techniques) to Determine Causes

247

(2)

Occurrence Rating

249

(1)

Current Controls and Detection Ratings

249

(1)

Detection Rating

250

(1)

Understanding and Calculating Risk

251

(2)

Action Plans and Results

253

(5)

Classification and Characteristics

254

(1)

Product Characteristics/``Root Causes''

255

(1)

Process Parameters/``Root Causes''

255

(1)

Driving the Action Plan

255

(3)

Linkages among Design and Process FMEAs and Control Plan

258

(2)

Getting the Most from FMEA

260

(2)

System or Concept FMEA

262

(1)

Design Failure Mode and Effects Analysis (DFMEA)

262

(6)

Objective

263

(1)

Timing

263

(1)

Requirements

263

(1)

Discussion

263

(1)

Forming the Appropriate Team

263

(1)

Describing the Function of the Design/Product

264

(1)

Describing the Failure Mode Anticipated

264

(1)

Describing the Effect of the Failure

264

(1)

Describing the Cause of the Failure

264

(1)

Estimating the Frequency of Occurrence of Failure

265

(1)

Estimating the Severity of the Failure

265

(1)

Identifying System and Design Controls

265

(1)

Estimating the Detection of the Failure

266

(1)

Calculating the Risk Priority Number

267

(1)

Recommending Corrective Action

267

(1)

Strategies for Lowering Risk: (System/Design) --- High Severity or Occurrence

267

(1)

Strategies for Lowering Risk: (System/Design) --- High Detection Rating

267

(1)

Process Failure Mode and Effects Analysis (FMEA)

268

(9)

Objective

268

(1)

Timing

268

(1)

Requirements

268

(1)

Discussion

269

(1)

Forming the Team

269

(1)

Describing the Process Function

269

(1)

Manufacturing Process Functions

269

(1)

The PFMEA Function Questions

270

(1)

Describing the Failure Mode Anticipated

270

(1)

Describing the Effect(s) of the Failure

271

(1)

Describing the Cause(s) of the Failure

272

(1)

Estimating the Frequency of Occurrence of Failure

273

(1)

Estimating the Severity of the Failure

273

(1)

Identifying Manufacturing Process Controls

273

(1)

Estimating the Detection of the Failure

274

(1)

Calculating the Risk Priority Number

275

(1)

Recommending Corrective Action

275

(1)

Strategies for Lowering Risk: (Manufacturing) --- High Severity or Occurrence

275

(1)

Strategies for Lowering Risk: (Manufacturing) --- High Detection Rating

276

(1)

Machinery FMEA (MFMEA)

277

(7)

Identify the Scope of the MFMEA

277

(1)

Identify the Function

277

(1)

Failure Mode

277

(1)

Potential Effects

278

(1)

Severity Rating

279

(1)

Classification

279

(1)

Potential Causes

279

(3)

Occurrence Ratings

282

(1)

Surrogate MFMEAs

282

(1)

Current Controls

282

(1)

Detection Rating

282

(1)

Risk Priority Number (RPN)

282

(1)

Recommended Actions

283

(1)

Date, Responsible Party

283

(1)

Actions Taken/Revised RPN

283

(1)

Revised RPN

284

(1)

Summary

284

(1)

Selected Bibliography

284

(3)

Reliability

287

(58)

Probabilistic Nature of Reliability

287

(1)

Performing the Intended Function Satisfactorily

288

(3)

Specified Time Period

288

(1)

Specified Conditions

289

(1)

Environmental Conditions Profile

289

(1)

Reliability Numbers

290

(1)

Indicators Used to Quantify Product Reliability

290

(1)

Reliability and Quality

291

(4)

Product Defects

291

(1)

Customer Satisfaction

292

(1)

Product Life and Failure Rate

293

(2)

Product Design and Development Cycle

295

(5)

Reliability in Design

296

(1)

Cost of Engineering Changes and Product Life Cycle

297

(1)

Reliability in the Technology Deployment Process

298

(1)

Pre-Deployment Process

298

(1)

Core Engineering Process

299

(1)

Quality Support

300

(1)

Reliability Measures --- Testing

300

(5)

What Is a Reliability Test?

300

(1)

When Does Reliability Testing Occur?

301

(1)

Reliability Testing Objectives

301

(1)

Sudden-Death Testing

302

(3)

Accelerated Testing

305

(1)

Accelerated Test Methods

305

(5)

Constant-Stress Testing

305

(1)

Step-Stress Testing

306

(1)

Progressive-Stress Testing

306

(1)

Accelerated-Test Models

306

(1)

Inverse Power Law Model

307

(1)

Arrhenius Model

308

(2)

AST/PASS

310

(2)

Purpose of AST

310

(1)

AST Pre-Test Requirements

311

(1)

Objective and Benefits of AST

311

(1)

Purpose of PASS

311

(1)

Objective and Benefits of PASS

312

(1)

Characteristics of a Reliability Demonstration Test

312

(2)

The Operating Characteristic Curve

313

(1)

Attributes Tests

313

(1)

Variables Tests

314

(1)

Fixed-Sample Tests

314

(1)

Sequential Tests

314

(1)

Reliability Demonstration Test Methods

314

(2)

Small Populations --- Fixed-Sample Test Using the Hypergeometric Distribution

315

(1)

Large Population --- Fixed-Sample Test Using the Binomial Distribution

315

(1)

Large Population --- Fixed-Sample Test Using the Poisson Distribution

316

(1)

Success Testing

316

(2)

Sequential Test Plan for the Binomial Distribution

317

(1)

Graphical Solution

318

(1)

Variables Demonstration Tests

318

(3)

Failure-Truncated Test Plans --- Fixed-Sample Test Using the Exponential Distribution

318

(1)

Time-Truncated Test Plans --- Fixed-Sample Test Using the Exponential Distribution

319

(1)

Weibull and Normal Distributions

320

(1)

Sequential Test Plans

321

(14)

Exponential Distribution Sequential Test Plan

321

(2)

Weibull and Normal Distributions

323

(1)

Interference (Tail) Testing

323

(1)

Reliability Vision

323

(1)

Reliability Block Diagrams

323

(2)

Weibull Distribution --- Instructions for Plotting and Analyzing Failure Data on a Weibull Probability Chart

325

(6)

Instructions for Plotting Failure and Suspended Items Data on a Weibull Probability Chart

331

(3)

Additional Notes on the Use of the Weibull

334

(1)

Design of Experiments in Reliability Applications

335

(1)

Reliability Improvement through Parameter Design

336

(1)

Department of Defense Reliability and Maintainability --- Standards and Data Items

337

(5)

References

342

(1)

Selected Bibliography

343

(2)

Reliability and Maintainability

345

(22)

Why Do Reliability and Maintainability?

345

(1)

Objectives

346

(1)

Making Reliability and Maintainability Work

346

(1)

Who's Responsible?

347

(1)

Tools

347

(1)

Sequence and Timing

348

(1)

Concept

349

(1)

Bookshelf Data

349

(1)

Manufacturing Process Selection

350

(1)

R&M and Preventive Maintenance (PM) Needs Analysis

350

(1)

Development and Design

350

(2)

R&M Planning

350

(1)

Process Design for R&M

351

(1)

Machinery FMEA Development

351

(1)

Design Review

352

(1)

Build and Install

352

(1)

Equipment Run-Off

352

(1)

Operation of Machinery

352

(1)

Operations and Support

353

(1)

Conversion/Decommission

353

(1)

Typical R&M Measures

353

(9)

R&M Matrix

353

(1)

Reliability Point Measurement

354

(1)

MTBE

354

(1)

MTBF

355

(1)

Failure Rate

355

(1)

MTTR

355

(1)

Availability

356

(1)

Overall Equipment Effectiveness (OEE)

356

(1)

Life Cycle Costing (LCC)

356

(1)

Top 10 Problems and Resolutions

357

(1)

Thermal Analysis

357

(2)

Electrical Design Margins

359

(1)

Safety Margins (SM)

359

(1)

Interference

360

(1)

Conversion of MTBF to Failure Rate and Vice Versa

361

(1)

Reliability Growth Plots

361

(1)

Machinery FMEA

361

(1)

Key Definitions in R&M

362

(2)

DFSS and R&M

364

(1)

References

365

(1)

Selected Bibliography

365

(2)

Design of Experiments

367

(90)

Setting the Stage for DOE

367

(5)

Why DOE (Design of Experiments) Is a Valuable Tool

367

(3)

Taguchi's Approach

370

(1)

Miscellaneous Thoughts

371

(1)

Planning the Experiment

372

(8)

Brainstorming

372

(1)

Choice of Response

373

(6)

Miscellaneous Thoughts

379

(1)

Setting Up the Experiment

380

(17)

Choice of the Number of Factor Levels

380

(2)

Linear Graphs

382

(1)

Degrees of Freedom

383

(1)

Using Orthogonal Arrays and Linear Graphs

383

(1)

Column Interaction (Triangular) Table

384

(1)

Factors with Three Levels

385

(1)

Interactions and Hardware Test Setup

385

(2)

Choice of the Test Array

387

(2)

Factors with Four Levels

389

(1)

Factors with Eight Levels

389

(1)

Factors with Nine Levels

390

(1)

Using Factors with Two Levels in a Three-Level Array

390

(1)

Dummy Treatment

390

(1)

Combination Method

390

(1)

Using Factors with Three Levels in a Two-Level Array

391

(1)

Other Techniques

391

(1)

Nesting of Factors

392

(1)

Setting Up Experiments with Factors with Large Numbers of Levels

392

(1)

Inner Arrays and Outer Arrays

393

(1)

Randomization of the Experimental Tests

394

(1)

Miscellaneous Thoughts

394

(3)

Loss Function and Signal-to-Noise

397

(8)

Loss Function and the Traditional Approach

397

(1)

Calculation of the Loss Function

398

(4)

Comparison of the Loss Function and Cpk

402

(1)

Signal-to-Noise (S/N)

403

(1)

Miscellaneous Thoughts

404

(1)

Analysis

405

(16)

Graphical Analysis

405

(2)

Analysis of Variance (ANOVA)

407

(1)

Estimation at the Optimum Level

408

(1)

Confidence Interval around the Estimation

409

(1)

Interpretation and Use

410

(1)

ANOVA Decomposition of Multi-Level Factors

410

(1)

S/N Calculations and Interpretations

411

(1)

Smaller-the-Better (STB)

412

(1)

Larger-the-Better (LTB)

413

(1)

Nominal the Best (NTB)

413

(2)

Combination Design

415

(3)

Miscellaneous Thoughts

418

(3)

Analysis of Classified Data

421

(9)

Classified Responses

422

(1)

Classified Attribute Analysis

422

(3)

Class 1

425

(1)

Class 2

426

(1)

Classified Variable Analysis

426

(2)

Discussion of the Degrees of Freedom

428

(1)

Miscellaneous Thoughts

429

(1)

Dynamic Situations

430

(11)

Definition

430

(1)

Discussion

431

(1)

Conditions

431

(1)

Analysis

432

(7)

Miscellaneous Thoughts

439

(1)

For Example 1

440

(1)

For Example 2

440

(1)

Parameter Design

441

(6)

Discussion

441

(1)

Example

441

(6)

Tolerance Design

447

(7)

Discussion

447

(1)

Example

448

(6)

Humidity

454

(1)

Testing

454

(1)

DOE Checklist

454

(1)

Selected Bibliography

455

(2)

Miscellaneous Topics --- Methodologies

457

(78)

Theory of Constraints (TOC)

457

(8)

The Goal

457

(1)

Strategic Measures

458

(1)

Net Profit, Return on Investment, and Productivity

459

(1)

Measurement Focus

460

(1)

Throughput versus Cost World

461

(1)

Obstacles to Moving into the Throughput World

461

(2)

The Foundation Elements of TOC

463

(1)

The Theory of Non-Constraints

463

(1)

The Five-Step Framework of TOC

464

(1)

Selected Bibliography

465

(1)

Design Review

465

(5)

Failure Mode and Effect Analysis (FMEA)

467

(3)

References

470

(1)

Selected Bibliography

470

(1)

Trade-Off Studies

470

(7)

How to Conduct a Trade-Off Study: The Process

471

(1)

Construct the Preliminary Matrix

471

(1)

Select and Assemble the Cross-Functional Team

472

(1)

Assign Team Members' Roles and Responsibilities

472

(1)

Assign Ranking Teams To Evaluate the Alternatives

473

(1)

Identification of Ranking Methods

473

(1)

Development of Standardized Documentation

474

(1)

Timing for Report out of Selection Process

474

(1)

Weight the Various Categories

474

(1)

Compile the Evidence Book

475

(1)

Present the Results

475

(1)

Glossary of Terms

476

(1)

Selected Bibliography

477

(1)

Cost of Quality

477

(34)

Cost Monitoring System

478

(1)

Standard Cost

478

(1)

Actual Costs

478

(2)

Variance

480

(1)

Cost Reduction Efforts

480

(1)

Concepts of Quality Costs

480

(1)

J. Juran

480

(1)

W.E. Deming

480

(1)

P. Crosby

481

(1)

G. Taguchi

481

(1)

Definition of Quality Components

481

(2)

Methods of Measuring Quality

483

(1)

Complaint Indices

484

(1)

Processing and Resolution of Customer Complaints

484

(1)

Techniques for Analyzing Data

484

(1)

Format for Presentation of Costs

485

(1)

Laws of Cost of Quality

485

(2)

Data Sources

487

(1)

Inspection Decisions

487

(1)

Prevention Costs (See Table 10.5)

487

(1)

Appraisal Costs (See Table 10.6)

487

(1)

Internal Failure Costs (See Table 10.7)

487

(1)

External Failure Costs (See Table 10.8)

487

(2)

Diagnostic Guidelines to Identify Manufacturing Process Improvement Opportunities

489

(1)

Diagnostic Guidelines to Identify Administrative Process Improvement Opportunities

490

(2)

Steps for Quality Improvement --- Using Cost of Quality

492

(1)

Procedure

492

(1)

Examples

492

(10)

Guideline Cost of Quality Elements by Discipline

502

(7)

Cost of Quality and DFSS Relationship

509

(2)

References

511

(1)

Selected Bibliography

511

(1)

Reengineering

511

(6)

Process Redesign

511

(1)

The Restructuring Approach

512

(1)

The Conference Method

513

(2)

The OOAD Method

515

(1)

Reengineering and DFSS

516

(1)

References

517

(1)

Selected Bibliography

518

(1)

Geometric Dimensioning and Tolerancing (GD&T)

518

(5)

References

523

(1)

Selected Bibliography

523

(1)

Metrology

524

(9)

Understanding the Problem

524

(1)

Metrology's Role in Industry and Quality

525

(2)

Measurement Techniques and Equipment

527

(1)

Purpose of Inspection

528

(1)

How Do We Use Inspection and Why?

529

(1)

Methods of Testing

529

(1)

Interpreting Results of Inspection and Testing

530

(1)

Technique for Wringing Gage Blocks

531

(1)

Length Combinations

532

(1)

References

533

(2)

Innovation Techniques Used in Design for Six Sigma (DFSS)

535

(18)

Modeling Design Iteration Using Signal Flow Graphs as Introduced by Eppinger, Nukala and Whitney (1997)

535

(4)

Rules and Definitions of Signal Flow Graphs as Introduced by Howard (1971) and Truxal (1955)

538

(1)

Basic Operations on Signal Flow Graphs

538

(1)

The Effect of a Self Loop

538

(1)

Solution by Node Absorption

539

(1)

References

539

(1)

Selected Bibliography

540

(1)

Axiomatic Designs

541

(6)

So, What Is an Axiomatic Design?

542

(1)

Axiomatic and Other Design Methodologies

542

(1)

Applying Axiomatic Design to Cars

543

(1)

New Designs

544

(1)

Diagnosis of Existing Design

544

(1)

Extensions and Engineering Changes to Existing Designs

544

(1)

Efficient Project Work-Flow

545

(1)

Effective Change Management

545

(1)

Efficient Design Function

545

(2)

References

547

(1)

Selected Bibliography

547

(1)

TRIZ --- The Theory of Inventive Problem Solving

548

(3)

References

551

(1)

Selected Bibliography

551

(2)

Value Analysis/Engineering

553

(46)

Introduction to Value Control --- The Environment

553

(2)

History of Value Control

555

(1)

Value Concept

556

(4)

Definition

556

(1)

Planned Approach

556

(1)

Function

557

(1)

Value

557

(1)

Develop Alternatives

558

(1)

Evaluation, Planning, Reporting, and Implementation

559

(1)

The Job Plan

559

(1)

Application

560

(1)

Value Control --- The Job Plan

561

(1)

Value Control --- Techniques versus Job Plan

562

(1)

Techniques

562

(1)

Information Phase

563

(19)

Define the Problem

563

(1)

Information Development

564

(1)

Information Collection

564

(1)

Cost Visibility

564

(1)

Project Scope

565

(2)

Function Determination

567

(1)

Function Analysis and Evaluation

567

(1)

Cost Visibility

568

(1)

Definitions

568

(2)

Sources of Cost Information

570

(1)

Cost Visibility Techniques

570

(1)

Technique 1 --- Determine Manufacturing Cost

571

(1)

Technique 2 --- Determine Cost Element

571

(1)

Technique 3 --- Determine Component or Process Costs

571

(1)

Technique 4 --- Determine Quantitative Costs

572

(1)

Technique 5 --- Determine Functional Area Costs

573

(1)

Function Determination

573

(1)

What Is Function?

574

(1)

Basic and Secondary Functions

574

(1)

Basic Functions

574

(1)

Secondary Functions

575

(1)

Function Analysis and Evaluation

575

(1)

Technique 1 --- Identify and Evaluate Function

575

(1)

Technique 2 --- Evaluate Principle of Operation

576

(1)

Technique 3 --- Evaluate Basic Function

576

(1)

Technique 4 --- Theoretical Evaluation of Function

576

(1)

Technique 5 --- Input Output Method

577

(1)

Technique 6 --- Function Analysis System Technique

577

(3)

Cost Function Relationship

580

(1)

Evaluate the Function

580

(2)

Creative Phase

582

(3)

Phase 1. Blast

584

(1)

Phase 2. Create

584

(1)

Phase 3. Refine

584

(1)

Evaluation Phase

585

(6)

Selection and Screening Techniques

585

(1)

Pareto Voting

585

(1)

Paired Comparisons

586

(1)

Evaluation Summary

587

(1)

Matrix Analysis

587

(2)

Example

589

(1)

Rank and Weigh Criteria

589

(1)

Evaluate Each Alternative

590

(1)

Analyze Results

591

(1)

Implementation Phase

591

(6)

Goal for Achievement

592

(1)

Developing a Plan

592

(1)

Evaluation of the System

593

(1)

Understanding the Principles

593

(1)

Organization

594

(2)

Attitude

596

(1)

Value Council

596

(1)

Audit Results

597

(1)

Project Selection

597

(1)

Concluding Comments

598

(1)

References

598

(1)

Selected Bibliography

598

(1)

Project Management (PM)

599

(18)

What Is a Project?

599

(2)

The Process of Project Management

601

(1)

Key Integrative Processes

602

(1)

Project Management and Quality

603

(1)

A Generic Seven-Step Approach to Project Management

603

(2)

Phase 1. Define the Project

603

(1)

Step 1. Describe the Project

603

(1)

Step 2. Appoint the Planning Team

604

(1)

Step 3. Define the Work

604

(1)

Phase 2. Plan the Project

604

(1)

Step 4. Estimate Tasks

604

(1)

Step 5. Calculate the Schedule and Budgets

604

(1)

Phase 3. Implement the Plan

605

(1)

Step 6. Start the Project

605

(1)

Phase 4. Complete the Project

605

(1)

Step 7. Track Progress and Finish the Project

605

(1)

A Generic Application of Project Management in Implementing Six Sigma and DFSS

605

(8)

The Value of Project Management in the Implementation Process

607

(1)

Planning the Process

607

(1)

Goal Setting

608

(1)

PM and Six Sigma/DFSS

608

(2)

Project Justification and Prioritization Techniques

610

(1)

Benefit-Cost Analysis

610

(1)

Return on Assets (ROA)

610

(1)

Return on Investment (ROI)

610

(1)

Net Present Value (NPV) Method

611

(1)

Internal Rate of Return (IRR) Method

611

(1)

Payback Period Method

612

(1)

Project Decision Analysis

612

(1)

Why Project Management Succeeds

613

(2)

References

615

(1)

Selected Bibliography

615

(2)

Limited Mathematical Background for Design for Six Sigma (DFSS)

617

(44)

Exponential Distribution and Reliability

617

(8)

Exponential Distribution

617

(1)

Probability Density Function and Cumulative Distribution Function

618

(1)

Probability Density Function (Decay Time)

618

(1)

Cumulative Distribution Function (Rise Time)

618

(1)

Reliability Problems

618

(1)

Constant Rate Failure

619

(1)

Example

619

(2)

Probability of Reliability

621

(1)

Control Charts

621

(1)

Continuous Time Waveform

621

(1)

Discrete Time Samples

621

(1)

Digital Signal Processing

622

(1)

Sample Space

622

(2)

Assigning Probability to Sets

624

(1)

Gamma Distribution

625

(15)

Gamma Distribution (pdf)

625

(1)

Gamma Function

626

(1)

Properties of Gamma Functions

626

(1)

Gamma Distribution and Reliability

627

(1)

Example 1: Time to Total System Failure

627

(1)

Gamma Distribution and Reliability

628

(4)

Reliability Relationships

632

(1)

Reliability Function

632

(1)

Data Failure Distribution

633

(1)

Failure Rate or Density Function

633

(1)

Hazard Rate Function

634

(1)

Relations between Reliability and Hazard Functions

634

(1)

Poisson Process

635

(1)

Characteristics of Poisson Process

636

(1)

Poisson Distribution

636

(3)

Example

639

(1)

Weibull Distribution

640

(4)

Three-Parameter Weibull Distribution

643

(1)

Taylor Series Expansion

644

(12)

Taylor Series Expansion

645

(4)

Partial Derivatives

649

(1)

Taylor Series in Two-Dimensions

649

(1)

Taylor Series of Random Variable (RV) Functions

650

(1)

Variance and Covariance

650

(1)

Functions of Random Variables

651

(1)

Division of Random Variables

651

(1)

Powers of a Random Variable

652

(1)

Exponential of a Random Variable

652

(1)

Constant Raised to RV Power

653

(1)

Logarithm of Random Variable

653

(1)

Example: Horizontal Beam Deflection

654

(1)

Example: Difference between Two Means

655

(1)

Miscellaneous

656

(2)

Closing Remarks

658

(1)

Selected Bibliography

658

(3)

Fundamentals of Finance and Accounting for Champions, Master Blacks, and Black Belts

661

(54)

The Theory of the Firm

661

(1)

Budgets

662

(1)

Our Romance with Growth

663

(1)

The New Industrial State

663

(1)

Behavioral Theory

663

(1)

Accounting Fundamentals

664

(15)

Accounting's Role in Business

664

(1)

Financial Reports

664

(1)

The Balance Sheet

664

(1)

Current Assets and Liabilities

665

(1)

Fixed Assets

665

(1)

Other Slow Assets

666

(1)

Current Liabilities

666

(1)

Working Capital Format

666

(1)

Noncurrent Assets

667

(1)

Noncurrent Liabilities

667

(1)

Shareholders' Equity

667

(1)

The Income Statement

667

(1)

Gross Profit

668

(1)

A Gaggle of Profits

668

(1)

Earnings per Share

669

(1)

The Statement of Changes

669

(1)

Sources of Funds or Cash

669

(1)

Use of Funds

670

(1)

Changes in Working Capital Items

670

(1)

The Footnotes

670

(1)

Accountants' Report

671

(1)

How to Look at an Annual Report

671

(1)

Recording Business Transactions

672

(1)

Debits and Credits

673

(1)

Sources and Uses of Cash

673

(1)

How Debits and Credits Are Used

673

(1)

The Balance Sheet Equations

673

(1)

Classification of Accounts

674

(1)

Recording Transactions

675

(1)

The Two Books of Account

675

(1)

The Trial Balance

676

(1)

The Mirror Image

676

(1)

Accrual Basis of Accounting

676

(1)

Accrual Basis versus Cash Basis

677

(1)

Details, Details

677

(1)

Birth of the Balance Sheet

678

(1)

Profits versus Cash

678

(1)

Things Are Measured in Money

678

(1)

Values Are Based on Historical Costs

678

(1)

Understanding Financial Statements

679

(9)

Assets

679

(1)

The Inflation Effect

679

(1)

Summary of Valuation Methods

679

(1)

Historical Cost

679

(1)

Liquidation Value

679

(1)

Investment or Intrinsic Value

680

(1)

Psychic Value

680

(1)

Current Value or Replacement Cost

680

(1)

Assets versus Expenses

680

(1)

Types of Assets

681

(1)

Financial Assets

681

(1)

Physical Assets

681

(1)

Operating Leverage

682

(1)

Determining the Value of Inventory

682

(1)

FIFO

682

(1)

LIFO

682

(1)

Weighted Average

683

(1)

Depreciation

683

(1)

Useful Life Concept

683

(1)

Depreciation as an Expense

684

(1)

Depreciation as a Valuation Reserve

684

(1)

Depreciation as a Tax Strategy

684

(1)

Depreciation as Part of Cash Flow

685

(1)

Straight Line

685

(1)

Sum-of-the-Years' Digits (SYD)

686

(1)

Double Declining Balance (DDB)

686

(1)

Unit of Production

687

(1)

Replacement Cost

687

(1)

Advantages of Accelerated Depreciation

687

(1)

Financial Statement Analysis

688

(7)

Ratio Analysis

688

(3)

Liquidity Ratios

691

(1)

Financial Leverage

692

(1)

Coverage Ratios

692

(1)

Earnings

692

(1)

Earnings Ratios

693

(1)

Le ROI

693

(1)

ROE: Return on Equity

694

(1)

ROA: Return on Assets

694

(1)

ROS: Return on Sales

694

(1)

Other Return Ratios

694

(1)

Financial Rating Systems

695

(4)

Bond Rating Companies

695

(1)

Moody's et al.

695

(1)

Moody's

696

(1)

Standard and Poor's

696

(1)

Ratings on Common Stocks

696

(1)

The S&P Rating Method

697

(1)

The Value Line Method

697

(1)

Good Ole Ben Graham

697

(1)

Commercial Credit Ratings

698

(1)

Dun & Bradstreet

698

(1)

Other Systems

699

(1)

Company and Product Life Cycle

699

(5)

Cash Flow

700

(1)

A Final Thought about Cash Flow

701

(2)

A Handy Guide to Cost Terms

703

(1)

Useful Concepts for Financial Decisions

704

(6)

The Modified duPont Formula

704

(1)

Breakeven Analysis

705

(1)

Contribution Margin Analysis

706

(1)

Price-Volume Variance Analysis

707

(1)

Inventory's EOQ Model

707

(1)

Return on Investment Analysis

708

(1)

Net Present Value (NPV)

709

(1)

Internal Rate of Return (IRR)

709

(1)

Profit Planning

710

(2)

The Nature of Sales Forecasting

710

(1)

The Plans Up Form

710

(1)

Statistical Analysis

711

(1)

Compound Growth Rates

711

(1)

Regression Analysis

711

(1)

Revenues and Costs

711

(1)

Departmental Budgets

711

(1)

How to Budget

712

(1)

Zero-Growth Budgeting

712

(1)

Selected Bibliography

712

(3)

Closing Thoughts about Design for Six Sigma (DFSS)

715

(10)

Appendix The Four Stages of Quality Function Deployment

725

(6)

Stage 1: Establish Targets

725

(1)

Stage 2: Finalize Design Timetables and Prototype Plans

725

(1)

Stage 3: Establish Conditions of Production

725

(1)

Stage 4: Begin Mass Production Startup

726

(1)

Tangible Benefits

726

(1)

Intangible Benefits

727

(1)

Summary Value

727

(1)

The QFD Process

727

(1)

Managing the Process

728

(3)

Selected Bibliography

731

(6)

Index

737

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Six Sigma and Beyond: Design for Six Sigma, Volume VI

Summary

Table of Contents

Supplemental Materials

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Six Sigma and Beyond: Design for Six Sigma, Volume VI

Summary

Table of Contents

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