六西格玛设计DFSS

1、Business Excellence Journey with DFSS & DFR,Intro BE July 2010,Page 2,The Journey,1998 Seagate adopts Six Sigmadefect reduction, cost savings,2001 DFSS in Product & Process Development,1999 Lean in Manufacturing & Supply Chain,Intro BE July 2010,Page 3,DFSS in the Beginning,Iterative Use of historic

2、al requests Test and re-test Short term estimates Isolated CTQ optimization,Predictive Requirements hierarchy Model building Long term estimates System optimization,Initial Approach: Top down Educate the masses in design centers - “DFSS Certified” DFSS Foundation 2 weeks of Statistics DFSS Project S

3、ystems Engineering 3 days Train the suppliers and factory BrB/BB/MBBs in DFSS,Intro BE July 2010,Page 4,Allows us to set “need-based” requirements for CTQs and to evaluate our capability to meet those requirements.,What Is Design for Six Sigma?,Design for Six Sigma (DFSS):,Is a process that focuses

4、on predictive product design.,Emphasizes the use of statistical methods to predict product quality early in the design process.,Is a complement to good engineering/decision making practices.,Intro BE July 2010,Page 5,Six Sigma Improvement Methodology,A high level Business need is identified(CTQ gap)

5、 Does a Current Business Process/Product exist to address the gap Are the Processes/Products that support your key outputs optimized but still not capable of meeting customer requirements? Is the solution or part of the solution a new process, product, or service. Does the capability of one or more

6、KPIV need to be improved to optimize KPOV?,Identify,Design,Optimize,Define,Analyze,Improve,Control,Measure,Validate,1,A,NO,YES,NO,YES,YES,NO,YES,NO,A,Intro BE July 2010,Page 6,Feasibility Point Tollgate,Exception Review,Perform Tradeoffs to Ensure that All CTQs Are Met,OK,Not OK,Not OK,Not OK,Valida

7、te,Optimize,Design,Identify,OK,Translate Into Critical To Quality (CTQ) Measures and Key Process/Product Output Variable (KPOV) Limits,Formulate Designs/Concepts/Solutions,Evaluate Designs,For Each Top Level CTQ, Identify Key Product/Process Input Variables (KPIVs),Identify Customer Requirements,Dev

8、elop Transfer Functions Between Key Input and Output Variables,Assess Process Capability to Achieve Critical Design Parameters and Meet CTQ Limits,Optimize Design,DFSS Scoring,Determine Tolerances,Test & Validation,Assess Performance, Failure Modes, Reliability and Risks,Validate The Measurement Sys

9、tems,Not OK,Exception Review,OK,Perform Tradeoffs to Ensure that All CTQs Are Met,Not OK,Statistical Design,Intro BE July 2010,Page 7,Six Sigma and Design for Six Sigma,Design for Six Sigma and “Standard” Six Sigma work together!,Defects,Lower Spec Limit,Upper Spec Limit,Design for Six Sigma,Design

10、robust products so that specs can be loosened,Intro BE July 2010,Page 8,Design Evolution,Evolving Design requirements Design rework Build and test performance assessment Performance and manufacturability after product is designed Quality is “tested in”,FROM,TO,Disciplined CTQ flow-down Controlled de

11、sign parameters Performance modeled and simulated Design for robust performance and manufacturability,REACTIVE,PREDICTIVE,Intro BE July 2010,Page 9,Key Elements,Systems relationships Transfer Functions, KPIV & KPOV Statistical Design: Meeting not only target but address variations in design Identify

12、, Design, Optimize, & Verify (IDOV),Intro BE July 2010,Page 10,Systems Engineering - Flowdown,QFD/FMEA,Intro BE July 2010,Page 11,Systems View Of a Hard Disc Drive,Customer CTQs,Elec/Interface,Servo-Mech,RSS-H/M,38 CTQs,111 Subsystem CTQs,Component CTQs,Intro BE July 2010,Page 12,Transfer Function,W

13、hat is a Transfer Function?,f(X1,X2, Xn),X1,X2,X3,Xn,Y,It is a relationship of the CTQ (Y) to the key input variables (Xs). It is not necessarily as rigorous as a process model. It is key to predicting product performance before building prototypes.,Intro BE July 2010,Page 13,Getting to the y = f(x1

14、, x2),“All models are wrong, some are useful.”- George Box,Physical Models - dedicated experts Explore design space run simulations with DOE Model management process Statistical Models DOE, Regression, Response Surface, etc Parametric data analysis especially for reliability MSA,Intro BE July 2010,P

15、age 14,Flowdown/Flowup Process,Identify Customer CTQs. Translate into System CTQs.,System,Intro BE July 2010,Page 15,After y = f(x1,x2.), then,Internally developed tool handles up to 20 transfer functions Runs Sensitivity Analysis, Monte Carlo simulation and determines PNC Optimizes for a Figure of

16、Merit (cost, PNC, Z-score, user specified) Helps set tolerances for all inputs,Transfer Functions,Screened Parts?,Input w Variations,What the customerwants,Optimize to a Figure of Merit,Allocate Optimized Specs,Meeting expectation?,Intro BE July 2010,Page 16,Design & Engineering Benefits,KPOVs & KPI

17、Vs defined by transfer function Clear ownership of CTQs Visibility for trade-off management,Intro BE July 2010,Page 17,DFSS Process Integration,Parts/Process/Performance Capability Flowup,CTQ Flowdown,Owners,Intro BE July 2010,Page 18,Prospects,Understanding customer needs Complete understanding of

18、systems relationships Considers not only the target but the variation in design Integrating models & simulators to estimate Probability of Non-Conformance (PNC) Not about the number 6 but a cultural change,Intro BE July 2010,Page 19,Design Opportunity,Must move quality effort here!,Easy to see Costl

19、y to fix,Difficult to see/predict Easy to fix,Defects are:,Intro BE July 2010,Page 20,6 Sigma vs. Optimal Sigma,Optimal Setting,ZST LEVEL,Cost to Design and Manufacture Product,Intro BE July 2010,Page 21,What worked,Product & Process Development culture transformed by DFSS More rigorous VOC process

20、Doing Systems Engineering vs components (organization change) Speaking the “same language” in CTQ flow down (requirements) Emphasis on transfer function development - Models, DOE, regression, etc. Using statistical thinking vs target only - Monte Carlo simulation, tolerance analysis, etc Applying DF

21、R early in product & technology development, FMEAs up front More data driven decisions,Avg Development Time,Intro BE July 2010,Page 22,But Something Still Needs Beefing Up,1998 Seagate adopts Six Sigma,2001 DFSS in Product & Process Development,2006 Revised Design for Reliability (DFR),1999 Lean in

22、Manufacturing & Supply Chain,Intro BE July 2010,Page 23,Design for Reliability,Many common tools DFSS enables achieving high quality at launch with nominal stress conditions DFR focuses on achieving high quality over time and across stress levels,DFSS,DFR,VOC,MSA,DOE,Control Plans,ANOVA,QFD,FMEA,Reg

23、ression,Flowdown,Environmental & Usage Conditions,Life Data Analysis,Physics of Failure,Accelerated Life Testing,Reliability Growth,Warranty Predictions,FA recognition,General Linear Model,Tolerancing,Sensitivity Analysis,Modeling,Hypothesis Testing,Intro BE July 2010,Page 24,Enhanced DFR Process,Up

24、front use of DFR Assessment Matrix in the development cycle to identify and address reliability issues,Modeling Physics of Failure,Intro BE July 2010,Page 25,Integration into Product Development,Intro BE July 2010,Page 26,The Journey Forward,Intro BE July 2010,Page 27,Integration into Product Develo

25、pment,Phase-Gates & Deliverables,Intro BE July 2010,Page 28,LEAN,SIX SIGMA,TOC,Value Stream Mapping Value-add Analysis Error-proofing 5S Cycle time analysis Benchmarking 5 whys Potential problem analysis Work measurement,Critical chain project mgmt Prerequisite tree Transition Tree,Throughput focus,

26、Current reality tree Future reality tree Conflict resolution,Traditional DMAIC toolset Traditional DFSS toolset DFR tools,Setup reduction Pull systems Total productive maintenance Shop floor management OEE Lean assessment Lean diagnostic 48 hour study Layout optimization Batch size reduction Time st

27、udies Work sampling Red flag analysis,Change Mgmt,Tools We Use,Intro BE July 2010,Page 29,Business Excellence,Factory & Delivery,Intro BE July 2010,Page 30,Product Planning Process,Platform Integration/Technology Alignment,Gen 1 Declare,CTU Declare,SAD or ECQ,Gen 2 Declare,EM Declare,MR,Design,Integ

28、ration,Qualification,Pilot,Ramp,Phase 0,Feasibility,Advanced Drive Development (ADD),POR Arch.,Mini DR,Mini MR,PTA,Frame- work MR,Drive Development ,Product and Technology Portfolio Management Bi-Annual Processes,EM Start,Gen 1 RR,Gen 2 RR,SLAM II Context Diagram,(Click here for Milestone Definition

29、s),# Months prior to SAD,Drive Development Product Phase-Based Processes,Seagate Confidential,Intro BE July 2010,Page 31,Learning Objectives,After completing this training, the student will be able to:,Tie together the tools and methodology covered in this class. Understand how DFSS, DFR and DMAIC a

30、re interrelated. Apply the knowledge gained to current projects.,IDOV Process,Intro BE July 2010,Page 33,Feasibility Point Tollgate,Exception Review,Perform Tradeoffs to Ensure that All CTQs Are Met,OK,Not OK,Not OK,Not OK,Validate,Optimize,Design,Identify,OK,Translate Into Critical To Quality (CTQ)

31、 Measures and Key Process/Product Output Variable (KPOV) Limits,Formulate Designs/Concepts/Solutions,Evaluate Designs,For Each Top Level CTQ, Identify Key Product/Process Input Variables (KPIVs),Identify Customer Requirements,Develop Transfer Functions Between Key Input and Output Variables,Assess P

32、rocess Capability to Achieve Critical Design Parameters and Meet CTQ Limits,Optimize Design,DFSS Scoring,Determine Tolerances,Test & Validation,Assess Performance, Failure Modes, Reliability and Risks,Validate The Measurement Systems,Not OK,Exception Review,OK,Perform Tradeoffs to Ensure that All CT

33、Qs Are Met,Not OK,Statistical Design,Intro BE July 2010,Page 34,for small-scale product design, process design,The Six Sigma DIDOV Phase Deliverables,Intro BE July 2010,Page 35,Identify Phase,Phase Deliverables,Deliverables Details,Identified CTQs System Diagrams CTQ Linkage via QFD Identified Gaps,

34、Phase Objectives,Who are the customers? What are their requirements? What are their most important requirements? What are the biggest gaps? What is the plan?,Possible Phase Tools,Project Charter or Problem Statement Voice of the Customer (VOC) Kano Analysis Quality Function Deployment (QFD) Structur

35、e and Context Diagrams FMEA Gap Analysis Stakeholder and Resource Charts,Intro BE July 2010,Page 36,Design Phase,Phase Deliverables,Deliverables Details,Lower Level CTQs Defined System and Subsystem ZST and PNC Transfer Functions Specifications and Tolerances,Phase Objectives,Who are the possible so

36、lutions? What is the best potential solution? What are the key inputs? What are the functional relationships?,Possible Phase Tools,Cause and Effect Matrix Measurement Systems Analysis Hypothesis Testing ANOVA / GLM / Residual Analysis DOE Correlation and Regression Response Surface Methodology TRIZ

37、Decision Analysis,Intro BE July 2010,Page 37,Optimize Phase,Phase Deliverables,Deliverables Details,All Levels of Scorecards Transfer Functions ZST and PNC Predictions Tradeoff Analyses Process Specifications and Optimized Tolerances,Phase Objectives,How sensitive to input variability? How sensitive

38、 to environmental variability? How meaningful are the specifications? What is the capability? How reliable is the design?,Possible Phase Tools,Capability Analysis Tolerancing Tools Sensitivity and Monte Carlo Analysis SeaDOT Analysis Single or Multiple Response Optimization Tools Reliability Methods

39、,Intro BE July 2010,Page 38,Validate Phase,Measured Scorecards Validated Transfer Functions Capability Analyses Initial Control Plans,Can you demonstrate a capable process? How stable is your process? What are the key factors to control? What control mechanisms are in place? What is the control plan

40、?,Possible Phase Tools,Capability Analysis Confirmatory Testing Control Plans Statistical Process Control Error Proofing,Phase Deliverables,Deliverables Details,Phase Objectives,Intro BE July 2010,Page 39,Whats Needed,RM Software & Business Process,Integration into Product Development Flow & Phase-G

41、ate Process,Tools Development & Model Management,Identify VOC, CTC, Environmental,System Level CTQs,Requirement Management common repository, data structure, CTQ dictionary, flowdown,Design & Optimize Transfer Functions Allocations,Tools Application simulators, models, DOEs, Monte Carlo, optimizatio

42、n, etc.,Verify Stress Test, MSA,Measurement Systems & Builds sample sizes, cost, qualification test, etc.,Appendix: DFSS Phase Review,Intro BE July 2010,Page 41,I8-1,DFSS Phase Review Questions,Identify Phase,Intro BE July 2010,Page 42,I8-1,DFSS Phase Review Questions,Design Phase,Intro BE July 2010

43、,Page 43,I8-2,DFSS Phase Review Questions,Optimize Phase,Intro BE July 2010,Page 44,I8-2,DFSS Phase Review Questions,Validate Phase,All Phases,Appendix: Misc,Intro BE July 2010,Page 46,Acronyms and Symbols,RSMResponse Surface Methodology RSSRoot Sum of Squares sstandard deviation of a sample s2Varia

44、nce of a sample Sp System Capability Index SDMStatistical Design Methods SESystems Engineering Sea.DOTSeagate Design Optimization Tool SEISoftware Engineering Institute SPCStatistical Process Control SSSum of Squares SSpSubsystem Capability Index S/WSoftware TTarget Level TFTransfer Function TolTolerance TTMTime to Market UCLUpper Confidence Limit (Upper Control Limit in SPC) USLUpper Spec limit VOCVoice of the Customer WCWorst Case xMean of a sample ZNumber of ss that can fit between Mean and Spec limit,I & TIntegration & Test Phase of a Program IDO