Six Sigma Fundamentals: A Complete Introduction to the System, Methods, and Tools

Design stage 1—Advanced engineering

Phase 1: Innovation targets for systems

Task / Chart

Purpose / Comments

I-1

Matrix data

Decide what business you are in.

I-2

New concept

Selection chart

"Blue Sky"

New directions for product.

I-3

Market research

Kano 3 arrows and survey

Results matrix

Determine voice of customer.

I-4

K-J and Tree

2 Levels (see Figure D.1)

Understand voice of customer.

Figure D.1: K-J and tree 2 levels

I - 5

A-1 Part 1

House of quality

Learn customer priorities.

I - 6

A-1 Quality characteristics

Purpose

  • Identify key items to measure and control.

  • Benchmarking/competitive analysis.

  • Preliminary targets.

I - 7

A-2 Voice of engineer (function) vs. Quality characteristics

  • Identify missing quality characteristics.

  • Identify over-design.

B-1 Part 1

Voice of engineering vs. Voice of customer

  • Learn engineering priorities (Saaty method).

  • Learn conflicts between voice of engineer and voice of customer.

  • Alternate approach to learn engineering priorities.

I-8

B-3 Factor analysis (Taguchi)

In the light of combined voice of customer and voice of engineer.

Breakthrough targets

  • Analyze needed breakthroughs (factor analysis).

  • Set preliminary breakthrough targets.

Phase 2 -: Innovation ideas for systems

I - 9

C-1 New technology vs. systems

In light of breakthrough targets

  • Identify potential new technology.

  • Select system changes based on new technology.

I -10

C-2 Part 1

Systems vs. functions

Identify key systems based on voice of engineer (functions).

I - 11

C-3 Part 1

Systems vs. Quality characteristics

Identify key systems based on quality characteristics.

I -12

B-2 Cost analysis

Total product (Preliminary)

In light of key systems and potential new technology, do preliminary cost targets.

I -13

B-1 Part 2

Identify target functions for cost reduction.

I - 14

C-2 Part 2

Identify target systems for cost reduction.

Phase 3 -: Innovation engineering for systems

I - 15

F-2 Reviewed dendogram

Draw a diagram of potential system and cost improvements based on data from I - 8 through I - 14 and record on reviewed dendogram.

I - 16

F-1, F-2, F-3 Value engineering Factor analysis, finite element method

Develop engineering breakthroughs on systems and cost using value engineering, factor analysis, finite element method and other tools of engineering breakthrough.

I -17

Revise cost analysis B-2 based on engineering breakthroughs

Evaluate competitive cost position based on eng. breakthroughs. If satisfactory, go on to step I - 18. If not satisfactory, review steps I - 13, I - 14, I - 15, and I - 16 for alternatives.

I - 18

Revise targets

A-1 based on engineering and cost breakthroughs

Check to see how new systems and new technology stack up against competitors.

I - 19

Cost / Benefit Analysis (see Figure D.2)

Figure D.2: Cost/Benefit analysis

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