Implementing Design for Six Sigma

John J. O'Neill, Georgette Belair

Description

Have your company’s products achieved what you hoped for – rapid customer uptake, high sales volume and revenue/profit? Can you produce them at high Sigma-levels for Critical to Quality requirements, resulting in high customer satisfaction and low return/warranty costs? Authors Belair and O’Neill will help you understand how your current new-product development process is performing by diagnosing its strengths and weaknesses, and then planning and implementing changes to improve your organization’s ability to deliver Six Sigma designs!!--nl--The main goal of Implementing Design for Six Sigma is to provide you a game plan to help you “move the ball down the field” – from your current product development world to one where DFSS has been embraced as a working part of your processes and culture. Whether the products you develop are made of metal and plastic, or money and mutual funds, this book will help you improve your development process so that you may deliver better products and services that your customers will want and want to pay for. From tangible products like cars and cough syrup to service products like mortgages and retirement plans, if you dig deeply into your new-product development process and follow the guidelines in this book, you can and will implement major improvements.-

Sujets

• Business
• Qualité, hygiène, sécurité, environnement
• Total Quality Management
• Gestion et management
• Economics

Informations

• Publié par: ASQ Quality Press
• Date de parution: 02 janvier 2007
• Nombre de lectures: 0
• EAN13: 9780873894067
• Langue: English
• Poids de l'ouvrage: 1 Mo

Extrait

FM_Belair6X9.qxd 6/20/06 11:26 AM Page i
Implementing
Design for
Six SigmaFM_Belair6X9.qxd 6/20/06 11:26 AM Page ii
Also available from ASQ Quality Press:
Leadership For Results: Removing Barriers to Success for People,
Projects, and Processes
Tom Barker
The Executive Guide to Improvement and Change
G. Dennis Beecroft, Grace L. Duffy, John W. Moran
Design for Six Sigma as Strategic Experimentation: Planning, Designing,
and Building World-Class Products and Services
H. E. Cook
Computer-Based Robust Engineering: Essentials for DFSS
Genichi Taguchi, Rajesh Jugulum, and Shin Taguchi
Defining and Analyzing a Business Process: A Six Sigma Pocket Guide
Jeffrey N. Lowenthal
Transactional Six Sigma for Green Belts: Maximizing Service and
Manufacturing Processes
Samuel E. Windsor
Design of Experiments with MINITAB
Paul Mathews
Failure Mode and Effect Analysis: FMEA From Theory to Execution,
Second Edition
D. H. Stamatis
The Certified Six Sigma Black Belt Handbook
Donald W. Benbow and T. M. Kubiak
The Certified Manager of Quality/Organizational Excellence Handbook:
Third Edition
Russell T. Westcott, editor
Business Performance through Lean Six Sigma: Linking the Knowledge
Worker, the Twelve Pillars, and Baldrige
James T. Schutta
Process Quality Control: Troubleshooting and Interpretation of Data,
Fourth Edition
Ellis R. Ott, Edward G. Schilling, and Dean V. Neubauer
To request a complimentary catalog of ASQ Quality Press publications,
call 800-248-1946, or visit our Web site at http://qualitypress.asq.org.FM_Belair6X9.qxd 6/20/06 11:26 AM Page iii
Implementing
Design for
Six Sigma
A Leader’s Guide—Getting the Most
from Your Product Development Process
Georgette Belair
John O’Neill
ASQ Quality Press
Milwaukee, WisconsinFM_Belair6X9.qxd 6/20/06 11:26 AM Page iv
American Society for Quality, Quality Press, Milwaukee 53203
© 2007
All rights reserved. Published 2006
Printed in the United States of America
12 11 10 09 08 07 06 5 4 3 2 1
Library of Congress Cataloging-in-Publication Data
Belair, Georgette, 1969–
Implementing design for Six sigma : a leader's guide : getting the most from your
product development process / Georgette Belair, John O'Neill. —1st ed.
p. cm.
Includes bibliographical references and index.
ISBN 0-87389-695-5 (alk. paper)
1. Six sigma (Quality control standard) 2. Total quality management.
I. O'Neill, John, 1956– II. Title.
TS156.B438 2006
658.57—dc22 2006016963
ISBN-10: 0-87389-695-5
ISBN-13: 978-0-87389-695-5
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
Web site at www.asq.org or http://qualitypress.asq.org.
Printed on acid-free paperFM_Belair6X9.qxd 6/20/06 11:26 AM Page v
This book is dedicated to the many people who have touched
our lives and to the organizations that have allowed us to
work with them, have celebrated with us when we’ve “hit
home runs,” and have been patient with us when the
inevitable mistakes have occurred.FM_Belair6X9.qxd 6/20/06 11:26 AM Page viFM_Belair6X9.qxd 6/20/06 11:26 AM Page vii
Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv
Chapter 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Is Your Product Development Process Helping You
Win the Game Today? . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Do You Even Have a Product Development Process? . . . . . 2
So How Does DFSS Work Its Magic? . . . . . . . . . . . . . . . . . 8
What We’ll Promise You . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Do You Have the Gottawanna? . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 2 What Is Design for Six Sigma? . . . . . . . . . . . . . . 15
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
What Is Six Sigma? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
The Idea of Improving Design Processes . . . . . . . . . . . . . . . 25
What Is DFSS: Narrow Sense? . . . . . . . . . . . . . . . . . . . . . . . 26
What Is DFSS: Broad Sense? . . . . . . . . . . . . . . . . . . . . . . . . 31
Key Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Chapter 3 What DFSS Can Do for You
and Your Company 35
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Financial Benefits of DFSS (for Senior Leaders) . . . . . . . . . 36
Reducing Internal Friction through DFSS
(for Middle Managers) . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
DFSS Personal Benefits for Product Developers:
What’s in It for Me? (WIIFM?) . . . . . . . . . . . . . . . . . . . . 41
One Company’s Product Development Improvement
Journey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Key Points 47
viiFM_Belair6X9.qxd 6/20/06 11:26 AM Page viii
viii Contents
Chapter 4 DFSS: The Method and Roadmap . . . . . . . . . . . 49
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
DMADVI: A Quick History and 50,000-Foot View . . . . . . . 50
Define Phase: Overview and Tools . . . . . . . . . . . . . . . . . . . . 54
Measure Phase: OvervieTools . . . . . . . . . . . . . . . . . . 57
Analyze Phase: Overview and Tools 61
Design Phase: OvervieTools . . . . . . . . . . . . . . . . . . . 66
Verify and Validate: Overview and Tools . . . . . . . . . . . . . . . 70
Implement: Overview Tools . . . . . . . . . . . . . . . . . . . . . . . . . 73
Key Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Chapter 5 Gap Analysis and Readiness
for the DFSS Journey . . . . . . . . . . . . . . . . . . . . . 77
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Why Do You Want to Do DFSS? 78
Gap Analysis 82
Quality-Side Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Gap Analysis: Current New Product
Development Processes . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Gap w Product Development
Organizational Structure . . . . . . . . . . . . . . . . . . . . . . . . . 90
Team-by-Team Gap Analysis . . . . . . . . . . . . . . . . . . . . . . . . 92
Prioritize the Development Process Improvements . . . . . . . 93
“A-Side” Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Leadership Commitment . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Tolerance and Motivation for Change . . . . . . . . . . . . . . . . . 101
Planning for Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Key Points: DFSS Gap Analysis . . . . . . . . . . . . . . . . . . . . . . 105
Chapter 6 Planning, Leading, and Implementing
DFSS 107
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Planning the Deployment . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Step 1. Define DFSS Goals and Charter Your
DFSS Team . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Step 2. Understand Gaps and Prioritize Changes;
Align the Organization 111
Step 3. Plan the Changes 113
Step 4. Pilot DFSS Changes, Measure Results, Roll
Out Full-Scale Changes . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Step 5. Monitor and Improve the DFSS Process . . . . . . . . . 129
Step 6. Integrate and Sustain the Gains . . . . . . . . . . . . . . . . 130
Dos and Don’ts to Successful DFSS Implementation . . . . . 130FM_Belair6X9.qxd 6/20/06 11:26 AM Page ix
Contents ix
Dos to Successful DFSS Implementation . . . . . . . . . . . . . . . 131
Don’ts to Avoid in Implementing DFSS . . . . . . . . . . . . . . . . 135
Key Points: Using This Book to Help You Along
in Your Implementation . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Chapter 7 Measuring Success . . . . . . . . . . . . . . . . . . . . . . . . 143
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
What and When to Measure . . . . . . . . . . . . . . . . . . . . . . . . . 143
DFSS Leading, or Early Deployment, Metrics . . . . . . . . . . . 144
DFSS Mid-Deployment, or In-Process, Metrics . . . . . . . . . 146
DFSS Lagging, or Independence, Metrics . . . . . . . . . . . . . . 149
Planning to Measure Your DFSS Success 151
DFSS Deployment Metrics Examples . . . . . . . . . . . . . . . . . 151
Who to Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
How to Measure 153
Key Points: Guide to Measuring Success . . . . . . . . . . . . . . . 154
Chapter 8 How to Know When the
Organization “Has It” . . . . . . . . . . . . . . . . . . . . . 155
Identifying the Success of Training . . . . . . . . . . . . . . . . . . . 156
Benchmarking Success Against Other
Organizations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Verifying Independence Day . . . . . . . . . . . . . . . . . . . . . . . . 158
Communicating Independe