Table of Contents

Title Page

Copyright Page

Dedication

Preface

Acknowledgements

Chapter 1 - Introduction

1.1 THE GOAL

1.2 DESIGN FOR SIX SIGMA - STATE OF THE ART

1.3 APPROACH

1.4 GUIDE TO THIS BOOK

Chapter 2 - Driving Growth through Innovation

2.1 DELIVERING ON THE PROMISE

2.2 CREATING A BETTER PROMISE

2.3 AMBIDEXTROUS ORGANIZATION

2.4 PLATFORMS FOR GROWTH

2.5 INNOVATION AND DESIGN

2.6 CONCLUSIONS

Chapter 3 - Process for Systematic Innovation

3.1 BALANCED INNOVATION PORTFOLIO

3.2 EFFECTIVE TEAMS FOR COLLABORATION

3.3 PROCESS FOR EXECUTING INNOVATION PROJECTS

3.4 PROVEN TECHNIQUES AND TOOLS

3.5 CLIMATE FOR INNOVATION

3.6 THE GOVERNANCE SYSTEM

Chapter 4 - Lean Six Sigma Essentials

4.1 ORIGINS OF SIX SIGMA

4.2 SIX SIGMA APPROACH

4.3 ORIGINS OF LEAN

4.4 LEAN SIX SIGMA: FASTER, BETTER, AND CHEAPER

Chapter 5 - Deploying Design for Lean Six Sigma

5.1 DEPLOYING DFLSS

5.2 DESIGN FOR LEAN SIX SIGMA ENTERPRISE

Chapter 6 - Capturing the Voice of the Customer

6.1 DEFINING ELEMENTS OF CUSTOMER - PRODUCER RELATIONSHIP

6.2 CUSTOMER EXPECTATIONS

6.3 METHODS OF COLLECTING CUSTOMER EXPECTATIONS

6.4 RESEARCH ETHICS

Chapter 7 - Design Axioms and Their Usefulness in DFLSS

7.1 DESIGN AXIOMS

7.2 DOMAIN THINKING

7.3 DESIGNING OF MTS SOFTWARE SYSTEM

7.4 DESIGNING A SYSTEM THAT WILL MARKET SPORTING GOODS

7.5 DESIGNING A FAN BELT/PULLEY SYSTEM

7.6 USE OF DESIGN PRINCIPLES IN AN ACADEMIC DEPARTMENT

7.7 DESIGNING A UNIVERSITY SYSTEM THAT WILL TEACH STUDENTS ONLY THROUGH THE INTERNET

Chapter 8 - Implementing Lean Design

8.1 KEY PRINCIPLES OF LEAN DESIGN

8.2 STRATEGIES FOR MAXIMIZING VALUE AND MINIMIZING COSTS AND HARM

8.3 MODULAR DESIGNS

8.4 VALUE ENGINEERING

8.5 THE 3P (PRODUCTION, PREPARATION, PROCESS) APPROACH

Chapter 9 - Theory of Inventive Problem Solving (TRIZ)

9.1 INTRODUCTION TO TRIZ

9.2 TRIZ JOURNEY

9.3 CASE EXAMPLES OF TRIZ

9.4 ROBUSTNESS THROUGH INVENTIONS

Chapter 10 - Design for Robustness

10.1 ENGINEERED QUALITY

10.2 ADDITIONAL TOPICS IN DESIGNING FOR ROBUSTNESS

10.3 ROLE OF SIMULATIONS IN DESIGN FOR ROBUSTNESS

10.4 EXAMPLE - CIRCUIT STABILITY DESIGN

10.5 PCB DRILLED-HOLE QUALITY IMPROVEMENT

10.6 DESIGN OF A VALVELESS MICROPUMP USING TAGUCHI METHODS

Chapter 11 - Robust System Testing

11.1 INTRODUCTION

11.2 METHOD OF SOFTWARE TESTING

11.3 MTS SOFTWARE TESTING (CASE STUDY 1)

11.4 CASE STUDY 2

11.5 CONCLUSIONS

Chapter 12 - Development of Multivariate Measurement System Using the ...

12.1 WHAT IS MAHALANOBIS-TAGUCHI STRATEGY?

12.2 STAGES IN MTS

12.3 SIGNAL-TO-NOISE RATIO - A MEASURE OF PREDICTION ACCURACY

12.4 MEDICAL CASE STUDY

12.5 CASE EXAMPLE 2: AUTO MARKETING CASE STUDY

12.6 CASE STUDY 3: IMPROVING CLIENT EXPERIENCE

12.7 IMPROVEMENT OF THE UTILITY RATE OF NITROGEN WHILE BREWING SOY SAUCE

12.8 APPLICATION OF MTS FOR MEASURING OIL IN WATER EMULSION

12.9 PREDICTION OF FASTING PLASMA GLUCOSE (FPG) FROM REPETITIVE ANNUAL HEALTH ...

References

Appendix A - TRIZ Contradiction Matrix

Appendix B - 40 TRIZ Inventive Principles

Appendix C - Some Useful Orthogonal Arrays

Appendix D - Equations for Signal-to-noise (S/N) Ratios

Appendix E - Related Topics of Matrix Theory

Index

This book is printed on acid-free paper.

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Published simultaneously in Canada

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Library of Congress Cataloging-in-Publication Data:

Jugulum, Rajesh.

Design for lean six sigma / Rajesh Jugulum, Philip Samuel. p. cm.

Includes index.

eISBN : 978-0-470-63169-0

1. Six sigma (Quality control standard) 2. Quality control. 3. Production control. I. Samuel, Philip. II. Title.

TS156.J84 2008
658.4’013 - dc22

2007039334

To the memory of my father, J. Gopala Char, who taught me how to be brave and courageous, and to my mother, J. Sarala Bai, and Rekha, Aaroh, and Anush (Rajesh Jugulum)

Preface

Every corporation on our planet is on a quest to outperform its rivals in two key business areas - managing its current business for maximizing profit and finding the future of its business for maximizing growth. The objective of the first task is to focus on activities and processes that enable flawless delivery of the promises to customers. The goal of the second task is to identify newer and better promises that will delight customers.

During the latest recessionary years in the United States and around the world, organizations have focused all their efforts on improving processes and gaining cost productivity - in many cases using the Lean Six Sigma approach or strategic redeployment or sourcing. This has led to a phenomenon where, for many companies, the coffers are overflowing, and for the first time in recent years, a near-term retreat from an age of expanding possibilities seems imminent.

Fear not, one might say, growth processes are your friends. Unfortunately, the picture is pretty grim there, too. Although growth is usually one of the top agenda for almost every corporation, most fail to sustain growth on the long term. Several researchers have shown that only about 10 to 15 percent of the companies have managed to outperform their rivals and stay on a growth curve for more than a few years in order to deliver above-average returns to their shareholders.

Usually, there are two paths to deliver growth - mergers and acquisitions (M&A) and organic growth. Both approaches have pretty dismal track records. Researchers from McKinsey, A. T. Kearney, PricewaterhouseCoopers, Boston Consulting Group and BusinessWeek have shown that about 60 to 80 percent of the M&A deals worth at least $500 million destroyed shareholder wealth within 18 months of closing. On the organic front, about 70 to 80 percent of the products that established companies put into the market fail.

Historically, growth processes have largely been believed to be at the mercy of random processes. This has generated a sense of risk and unpredictability for the managers responsible for delivering results in a predictable fashion to shareholders. We believe that investing in growth opportunities does not have to be such a gamble. It is through the understanding and leveraging of the key variables responsible for innovation and growth that we can establish a predictable, scalable, and repeatable process. This is the focus of this book.

The book outlines a holistic Design for Lean Six Sigma (DFLSS) approach that businesses can adopt to energize their innovation process, perfect their product introduction process, and improve their new product/service development process. It also addresses the end-to-end DFLSS deployment process with a road map that promises a significantly improved and highly effective methodology for revenue productivity. Besides the road map, the book presents discussions on topics such as capturing voice of the customer (VOC), driving growth for innovation, design for robustness, axiomatic design, and theory of inventive problem solving (TRIZ), as they are considered very important to DFLSS. The book also presents a novel approach for system testing that can be used in validation phase of the DFLSS approach. Several other tools and techniques that can be used in conjunction with DFLSS road map are provided in the book. Much literature already exists concerning these tools and techniques.

In Six Sigma deployment, one of the most challenging aspects is to develop metrics to measure success of the system (it could be process, product, or service related). Quite often, we will come across situations where we have to make decisions based on more than one variable or characteristic of the system. These systems are called multivariate systems. Examples of multivariate systems include medical diagnosis systems, manufacturing inspection system, face or pattern recognitions systems, and fire alarm sensor systems. In the last chapter of this book we describe Mahalanobis-Taguchi Strategy (MTS) and its applicability to develop multivariate measurement system. The number of case applications of this method is increasing significantly.

Lean Six Sigma has been successfully applied in a variety of industries and functions to solve business problems and improve performance of products, processes, and services. Designing a product, process, or service to provide the intended function at the lowest cost with Six Sigma quality level (3.4 defects per million opportunities) of value for customers is Design for Lean Six Sigma (DFLSS). This book provides a structured, systematic, and disciplined methodology to execute the design process without reducing the importance of the designer’s intuition and design experience. This, in turn, strikes a balance between rigor and creativity, resulting in optimal design cycle times.

This book will be helpful for various types of audience:

• Top executives

• DFLSS/ Lean Six Sigma leaders

• Master Black Belts

• Lean masters

• Lean experts

• Black Belts

• Statisticians

• Healthcare experts

• Software designers and testers

• Pattern recognizers

• Banking executives

• Financial market consultants

• Academic community, as DFLSS can be considered as industrial and system engineering activity

The book will help them to accomplish the following:

• Understand DFLSS methodologies, along with various tools, concepts, and principles that are embedded in the DFLSS roadmap

• Successfully deploy DFLSS methodology in a systematic way

• Reduce incidences of fire fighting and time of development

• Bring innovative products in the market

• Maximize return on investment by effectively integrating processes, knowledge, and people

• Become self-sufficient in learning and deployment of DFSS method

There are several books on the subject of Design for Six Sigma (DFSS). We consider this book unique because of structured road map and some of the newer tools and techniques that can be used to successfully deploy DFLSS. If the contents of this book change the mindset of executives, engineers, managers, and other DFLSS/Lean Six Sigma leaders to think differently and apply DFLSS differently, it will have served a fruitful purpose.

Rajesh Jugulum Philip Samuel

Acknowledgments

Writing the book Design for Lean Six Sigma has been challenging and enjoyable. The successful completion of this book would not have been possible without help from many outstanding and talented people.

First, we would like to thank Dr. Genichi Taguchi for his tireless efforts to disseminate robust engineering knowledge by way of teaching, consulting, writing the articles and the books. We are also grateful to him for allowing us to use some of his examples. We believe that robust engineering is essential in DFLSS methodology.

Our special thanks are due to Dr. Nam P Suh, president of KAIST and professor at MIT, for developing axiomatic design theory that benefits the industry and DFSS practitioners in a significant way. We are also thankful to him for permitting us to use some case studies from his books on Axiomatic Design and Theory of Complexity.

Thanks are also due to Dr. Daniel Frey, professor at MIT, for his support and involvement in robustness through inventions work that can be considered as part of extended TRIZ methodology.

We are also thankful to Dr. Il Yong Kim of Queen’s University, Canada, and Dr. Akira Tezuka of National Institute of Advanced Industrial Science and Technology, Japan, for allowing us to publish the work on micropump robust design.

We also wish to thank Mr. R. C. Sarangi and Professor A. K. Choudhury for their help in PCB drilled-hole quality-improvement study. We would like to thank Dr. Leslie Monplaisir and Mr. Mahfoozulhaq Mian for their involvement in the TRIZ case example presented in the book.

We are grateful to Breakthrough Management Group (BMG) for allowing us to draw from its intellectual property and from overall client experiences.

We are very grateful to John Wiley for giving us an opportunity to publish this book. We are particularly thankful to our editor, Mr. Bob Argentieri, for his continued cooperation and support from the beginning. He has been quite patient and flexible with us in accommodating our requests. We would also like to thank Mr. Daniel Magers, the editorial assistant, and Ms. Nancy Cintron, production editor for their continued cooperation and support in this effort.

Finally, we would like to thank our families, especially Lisa Samuel and Rekha Jugulum, for their understanding and support throughout this effort.

Chapter 1

Introduction

This introductory chapter defines the goals of this book with a structured approach to successfully deploy Design for Lean Six Sigma (DFLSS) in any organization. The chapter introduces DFLSS road map that will form a basis for the entire book. The chapter also provides summaries of various chapters in the book and their relation to with each other. It also provides a discussion on the differences between this book and other DFSS books in the market.

1.1 THE GOAL

The goal of this book is to outline a holistic DFLSS approach that businesses can adopt to energize their innovation process, perfect their product introduction process, and improve their new product/service development process. This book will also address the end-to-end DFLSS deployment process with a road map that promises a significantly improved and highly effective methodology compared to other problem solving and design approaches.

Lesen Sie weiter in der vollständigen Ausgabe!

Lesen Sie weiter in der vollständigen Ausgabe!

Lesen Sie weiter in der vollständigen Ausgabe!

Lesen Sie weiter in der vollständigen Ausgabe!

Lesen Sie weiter in der vollständigen Ausgabe!

Lesen Sie weiter in der vollständigen Ausgabe!

Lesen Sie weiter in der vollständigen Ausgabe!

Lesen Sie weiter in der vollständigen Ausgabe!

Lesen Sie weiter in der vollständigen Ausgabe!

Lesen Sie weiter in der vollständigen Ausgabe!

Lesen Sie weiter in der vollständigen Ausgabe!

Lesen Sie weiter in der vollständigen Ausgabe!

Lesen Sie weiter in der vollständigen Ausgabe!

Lesen Sie weiter in der vollständigen Ausgabe!

Lesen Sie weiter in der vollständigen Ausgabe!

Lesen Sie weiter in der vollständigen Ausgabe!

Lesen Sie weiter in der vollständigen Ausgabe!

Lesen Sie weiter in der vollständigen Ausgabe!

Lesen Sie weiter in der vollständigen Ausgabe!