Six Sigma and Beyond: Design for Six Sigma, Volume VI

STAGE 3: ESTABLISH CONDITIONS OF PRODUCTION

Primary emphasis is process design.

• Critical component targets and tolerances related to prototype processing conditions

• Optimization experiments performed as needed

• Significant control items and means of control established

• Process FMEA/FTA/mistake proofing methods established

• Further need for breakthroughs defined

• Trial runs used to verify forecasted process stability, capability, adequacy of control points, and product quality

• Output should be QA method providing excellent results with minimum factory effort

• Process quality planning matrices generated

• Leadership of the QFD process transferred from engineering to manufacturing when the decision to go ahead with mass production is made

• Evaluate probability of success of pending mass production program

• Discuss details of quality assurance system