DFSS-Design for six sigma is covered in the following topic areas:
Design for six sigma is the suggested method to bring order to product design. analysis has shown that 70-80% of all quality problems are design related. Emphasis on manufacturing side alone will concentrate at the tail end of the problem solving process. The emphasis should be at the front end. Problem solving at the downstream end is more costly and time consuming than fixing it at the source.
Why Design for Six Sigma
NIST in 1999 reported that the automotive supply chain lost at least a billion dollars a year due to poor interoperability of digital designed product data.
There has been considerable emphasis in recent years by American industry in downsizing, restructuring, process redesign, and instituting cost containment, etc. These methods are directed at holding the line on cost. Gary Hamel describes this as denominator management.
In the business world, the equation for return on investment, or return on net operating assets, has both a numerator - net income, and a denominator - investment. Managers have found cutting the denominator, investment in people, resources, materials, or other assets is an easy way to make the desired return on investment rise (at least short term).
To grow the numerator of the equation, requires a different way of thinking. That thinking must include ways to increase sales or revenues. One of the ways to increase revenues must include introducing more new products for sale to customers.
Cooper R. states that new products account for a large percentage of company sales (40%) and profits (46%). of course, not every new product will survive. Two Studies listed below provide some statistics:
Table 1.1 indicates a large amount of ideas are needed. These ideas are sorted, screened and evaluated in order to obtain feasible ideas, which enter the development stage, pass into launch stage and become successful products.
To grow the numerator Cooper R. provides more details of how winning products are obtained:
There are many product development processes to choose from. Rosenau suggests that the former "relay race" process (one function passing the product from marketing to engineering to manufacturing and back through the loop) is obsolete. Multi-functional team activities involving all departments are necessary for effectiveness and speed to market. The Process is comprised of 2 parts: a "fuzzy front end"(idea generation and sorting) and new product development(NPD).
The complete NPD process includes 5 activities: