Design for Six Sigma as Strategic Experimentation

Harry E. Cook

Description

Design for Six Sigma as Strategic Experimentation develops a practical, science-based methodology for guiding the product realization process for highly-competitive markets. Forecasts of cash flow, market share, and price are used to select the final design from among the alternatives considered. A single formalism is used to integrate the tasks and responsibilities of marketing research, product planning, finance, design, engineering, and manufacturing within the overall product realization process. The targeted audiences for this book are graduate engineers, statisticians, and scientists who are or who soon will be involved in planning, designing, manufacturing, and servicing products for highly-competitive markets. "This book is a significant contribution to statisticians, systems and industrial engineers interested in the big picture. It has the potential to increase the relevance of statistical analysis and improve the statistical ability of system engineers to deal with new product design using economic considerations. Teachers, students and practitioners will find the book a useful addition to their libraries." Ron S. Kenett PA Ranaana, Isrrael (from Quality Progress magazine) "The book is an important path-breaking contribution to the critical societal need to more closely link engineering with business and other broad societal issues...Employing the approaches has the clear potential for achieving competitive advantage for corporations that grow capacity to use these tools and insights as additions to existing Six Sigma and Product Development improvement initiatives." Chris Magee Professor of the Practice of Mechanical Engineering and Engineering Systems and Director of the Center for Innovation in Product Development Massachusetts Institute of Technology

Sujets

• Business
• Qualité, hygiène, sécurité, environnement
• Total Quality Management
• Gestion et management
• Seis Sigma
• Product management
• Economics
• Six Sigma

Informations

• Publié par: ASQ Quality Press
• Date de parution: 04 novembre 2004
• Nombre de lectures: 1
• EAN13: 9780873892681
• Langue: English
• Poids de l'ouvrage: 2 Mo

Extrait

H1234 Cook c00 FMaQ5.qxd 12/7/04 4:20 PM Page i
Design for Six Sigma as
Strategic ExperimentationH1234 Cook c00 FMaQ5.qxd 12/7/04 4:20 PM Page ii
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To request a complimentary catalog of ASQ Quality Press publications, call
800-248-1946, or visit our Web site at http://qualitypress.asq.org.H1234 Cook c00 FMaQ5.qxd 12/7/04 4:20 PM Page iii
Design for Six Sigma as
Strategic Experimentation
Planning, Designing, and Building
World-Class Products and Services
H. E. Cook
ASQ Quality Press
Milwaukee, WisconsinH1234 Cook c00 FMaQ5.qxd 12/7/04 4:20 PM Page iv
American Society for Quality, Quality Press, Milwaukee 53203
© 2005 by
All rights reserved. Published 2005
Printed in the United States of America
12 11 10 09 08 07 06 05 5 4 3 2 1
Library of Congress Cataloging-in-Publication Data
Cook, H. E. (Harry E.)
Design for six sigma as strategic experimentation : planning, designing, and building
world-class products
and services / H. E. Cook.
p. cm.
Includes bibliographical references and index.
ISBN 0-87389-645-9 (alk. paper)
1. Product management. I. Title.
HF5415.15.C657 2005
658.4′012—dc22 2004025739
ISBN 0-87389-645-9
No part of this book may be reproduced in any form or by any means, electronic,
mechanical, photocopying, recording, or otherwise, without the prior written permission
of the publisher.
Publisher: William A. Tony
Acquisitions Editor: Annemieke Hytinen
Project Editor: Paul O’Mara
Production Administrator: Randall Benson
ASQ Mission: The American Society for Quality advances individual, organizational,
and community excellence worldwide through learning, quality improvement, and
knowledge exchange.
Attention Bookstores, Wholesalers, Schools, and Corporations: ASQ Quality Press books,
videotapes, audiotapes, and software are available at quantity discounts with bulk
purchases for business, educational, or instructional use. For information, please contact
ASQ Quality Press at 800-248-1946, or write to ASQ Quality Press, P.O. Box 3005,
Milwaukee, WI 53201-3005.
To place orders or to request a free copy of the ASQ
Quality Press Publications Catalog, including ASQ
membership information, call 800-248-1946. Visit our
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Printed on acid-free paperH1234 Cook c00 FMaQ5.qxd 12/7/04 4:20 PM Page v
To ValleH1234 Cook c00 FMaQ5.qxd 12/7/04 4:20 PM Page viH1234 Cook c00 FMaQ5.qxd 12/7/04 4:20 PM Page vii
Contents
List of Figures and Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxv
Chapter 1 Product Management and the Fundamental Metrics . . . . . . . . . 1
1.1 Six Sigma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 The Fundamental Metrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Managing the Enterprise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Guiding DFSS/SE 7
1.5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Chapter 2 Product Value and Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Monopoly 19
2.2 Value Curves and the Cost of Inferior Quality . . . . . . . . . . . . . . . . . . . . . . . 21
2.3 Examples of Value Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.4 Demand and Price Analysis for Value Trends of Products in a Segment . . . 35
2.5 Empirical Price and Value Ranges for a Segment . . . . . . . . . . . . . . . . . . . . . 38
2.6 Direct Value (DV) Method 39
2.7 Intuitively Estimated Value Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.8 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Chapter 3 System Level Design and Strategic Experimentation . . . . . . . . . . 47
3.1 Entrepreneurial Engineering and the Systems Viewpoint . . . . . . . . . . . . . . . 47
3.2 System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.3 Strategic Experiment Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.4 Summary 62
References 62
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viii Contents
Chapter 4 Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.1 Statistical Distributions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.2 “Law of Variances” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.3 DV Survey Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Chapter 5 Role of Variation on Product Value . . . . . . . . . . . . . . . . . . . . . . . . 85
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.2 Unweighted Value Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.3 Weighted Parabolic Expression for the Value of a Distribution
for Trial (q) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.4 Analysis of Shaft and Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.5 Robustness 94
5.6 Uncertainty in Population Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.7 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Chapter 6 Design of Shear Pin Using Monte Carlo Simulation . . . . . . . . . . 105
6.1 Nature of Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6.2 Computing Value Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6.3 Scaling Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6.4 Monte Carlo Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6.5 Value Improvement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.6 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
References 113
Chapter 7 Level 1: Multiple Regression with Pooled Variances . . . . . . . . . . 115
7.1 Historical Analysis versus Controlled Experimentation . . . . . . . . . . . . . . . . 115
7.2 Levels of Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7.3 The Regular Least Square (RLS) Linear Regression Model . . . . . . . . . . . . . 117
7.4 Use of the Spreadsheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7.5 Level 1 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.6 LOF Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.7 Hierarchical Rules of Thumb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.8 Examination of Residuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.9 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Chapter 8 Level 2: Satterthwaite’s df and Approximate t-Test . . . . . . . . . . . 137
8.1 Flow Chart for Level 2 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
8.2 Satterthwaite’s Approximate t-test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
8.3 Level 2 Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140H1234 Cook c00 FMaQ5.qxd 12/7/04 4:20 PM Page ix
Contents ix
8.4 Level 1 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
8.5 Summary