Design for Six Sigma (DFSS)

Design for Six Sigma (DFSS) is about getting it right in the first place so you don't need to fix anything with DMAICT.

DFSS is the proven methodology that is used for the design of defect free products and processes that satisfy the customer profitably. It ensures that new products or processes are designed to deliver consistent performance that is robust against the unwanted sources of variation that will be experienced. DFSS incorporates statistical methods to predict design performance, providing quantifiable confidence in the ability of the new product or process to consistently meet the customer requirements.

Trained Red Belts in Design for Six Sigma will be able to apply the DFSS methodology to achieve:

• improved product performance
• improved quality
• improved efficiency in the New Product Introduction (NPI) process
• a more effective Integrated Product Team (IPT) approach to design
• reduction in the number of product redesigns
• confidence in delivering products that better meet customer requirements

Who should attend this course?

The course is aimed at product design and manufacturing teams. Since DFSS embraces the entire product lifecycle, other members of the Integrated Product Team (marketing, purchasing, etc.) should attend certain modules of the course.

At the end of the training attendees will:

• know when and how to use the extensive Design for Six Sigma tool-set to make data driven design decisions
• be able to incorporate variation into the design process to achieve robust product performance
• be able to capture customer requirements and integrate them into the design of the product
• be able to participate actively and effectively in the Integrated Product Team

The complete training comprises of 6 modules of 27 days duration. We can tailor the number of modules and their content to suit the nature of your business.

Each module is separated by approximately one month so that delegates can put into practice what they have learnt. During the course examples will be run using Minitab, Crystal Ball and QFD Designer.

Agenda for DFSS Module 1
Day 1	Day 2	Day 3
Introductions The why and what of DFSS Roles and Responsibilities Overview of the Indentify Phase Review of Day 1	Customer Requirements Textural Analysis Identifying Customers and Eliciting Requirements Review of Day 2	Viewpoint Analysis Functional Modelling Review of Day 3
Day 4	Day 5
Quality Function Deployment Quality Function Deployment Review of Day 4	Sensitivity Analysis Planning for Requirements Capture What Next and Review

Agenda for DFSS Module 2
Day 1	Day 2	Day 3
Variation, Normal Theory and Span Data Sampling Theory Review of Day 1	Gauge R&R: Continuous Data Gauge R&R: Attribute Data Introduction to Hypothesis Tests Review of Day	Hypothesis Tests: Z and t tests ANOVA: Type 1, Type 2, 1-way, 2-way, Balanced, GLM Model specification Fixed, Random, Nested and Crossed terms Hypothesis Tests continued Review of Day 3
Day 4	Day 5
Proportion and Chi-squared tests Non-parametric tests Process Capability: Continuous Data using Z values Process Capability: Classic metrics Review of Day 4	Process Capability: Discrete Data Managing CTQs The Score Card Course Review

Agenda for DFSS Module 3
Day 1	Day 2	Day 3
Introduction Review Design Phase Overview Understanding Sources of Variation Generating Design Concepts Review of Day 1	Generating Design Concepts Concept Matching and Selection Concept Matching and Selection Review of Day 2	Capturing Sources of Variation QFD2 What Next and Review

Agenda for DFSS Module 4
Day 1	Day 2	Day 3	Day 4
Introduction Introduction to Robust Design and Design of Experiments Full Factorial Design of Experiments Review of Day 1	Fractional Factorial and Screening DoE Noise in DoE Review of Day 2	Centre Points and Non-Linear Designs Response Surface Methods Review of Day 3	Design of Experiments Wash up Exercise What Next and Review Review of Day 4

Agenda for DFSS Module 5
Day 1	Day 2	Day 3
Introduction QFD3 Introduction to Statistical Design Review of Day 1	Statistical Design for Linear Systems Robustness Metrics Review of Day 2	Parameter Design for Non-Linear Systems Parameter Design for Non-Linear Systems Review of Day 3
Day 4	Day 5
Parameter Design using Robust DoE Parameter Design using Robust DoE Review of Day 4	Parameter Design using Robust DoE Tolerance Design What Next and Review

Agenda for DFSS Module 6
Day 1	Day 2	Day 3
Introduction Review QFD4 Design for Assembly Review of Day 1	Statistical Tolerancing and Control Statistical Tolerancing and Control Review of Day 2	Reliability – FMEA and Modelling using Fault Trees, Block Diagrams Reliability – Evaluation Introduction Reliability - Growth Review of Day 3
Day 4	Day 5
Reliability – Constant Failure Rates Reliability – Test Planning in Minitab Reliability – Sequential Testing Reliability – Modelling in Minitab Review of Day 4	Reliability – Accelerated Testing Reliability – Binary Response Analysis Course Overview and Summary Course Examination

For full programme details

Email: info@bourton.co.uk