01926 633333Performance over Price – Reliability Without Over Engineering
The Problem
The client was fully aware that maintaining a lead in the market required a highly skilled workforce combined with the ability to adopt and refine proven design methodologies, tools, and techniques. They also realized that continuing with their existing approach would not achieve the “next level” of performance that they required and approached Bourton Group to understand how Design for Six Sigma (DfSS) could help them.
The Solution
Working alongside six of the clients’ IPTs (Integrated Project Teams), Bourton Group developed a refined design process based upon the DCOV (Define – Characterise – Optimise- Verify) approach to Design for Six Sigma and the client’s existing “gated” engineering process.
The six IPTs went through a certified training programme before running a pilot version of the new design methodology. The pilot was to run for one complete design cycle, heavily supported by the team of experts from Bourton Group. The new approach quickly demonstrated benefits by dramatically increasing the fidelity of designs within a similar design time and cost envelope and solving some previous intractable engineering problems.
With the pilot phase completed, the approach was steadily rolled out across all IPTs. The success of the pilot and subsequent roll-out has led to the development of awareness courses for managers to assist the spread of the robust design programme throughout the organisation and the establishment of local Champions to take pressure off the central team, ensure sustainability, and minimise constraints on the pace of implementation.
The Benefits
By embedding robust design methods:
- Reliability improved, reducing costly failures and downtime.
- Development costs fell as fewer late‑stage fixes were needed.
- Products reached the market faster with less risk.
- A strong internal network of experts was created to ensure sustainability.
The organisation has already seen major financial benefits and continues to target significant ongoing savings.
What Rolls-Royce said about us
“Working with Bourton helped us build robust design into our way of working. Their training and support gave our teams the skills and confidence to design right the first time, saving time, money, and reducing risk.”