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

F

F.W. Dodge reports , 145

Fabrication process, 206

Factors, 380

ANOVA (analysis of variance) decomposition of, 410 “411

choosing number of levels, 380 “382

decomposition of, 410

effects of, 424 “425

eight-level, 389

four-level, 389

nesting of, 392

nine-level, 390

test matrix for, 377

three-level , 385, 391, 392

in three-level arrays, 390 “391

two-level , 390

types of, 393

Facts, and change management, 127

Fail safe design, 208

Failure, 362

causes of, 246 “247, 264 “265, 272 “273

constant rate, 619

costs of, 483, 490 “491

cumulative function, 635

detecting, 267, 274 “275

effects of, 264, 271 “272

free time, 643

logs of, 282

methods of determining, 247 “249

occurrence rating, 249, 265, 273

probability of, 618 “620

severity of, 265, 273

user costs, 484

Failure Definition and Scoring Criterion (book), 288

Failure modes, 240

cause and occurrence, 246 “247

describing, 264, 270 “271

design controls for, 249 “250

detection rating, 250

determining, 66, 247 “249

effects of, 243 “245, 278

examples of, 242 “243

in FMEA (failure modes and effects analysis), 242 “244

in function diagrams, 66

in machinery FMEA, 277 “278

process controls for, 249 “250

severity rating, 244 “245

Failure modes and effects analysis. see FMEA

Failure rate, 633

conversion to MTBF (mean time between failures), 361

in failure-truncated tests, 318

as measure of product reliability, 290

and product life, 293 “295

in R&M (reliability and maintainability), 355

and system failure, 629

Failure reporting, analysis, and corrective action system (FRACAS), 341, 352, 362

Failure-truncated tests, 318 “319

FAST (functional analysis system technique), 567, 577 “580, 712

Fatigue, 294

Fault tree analysis. see FTA

Fax machines, in customer/supplier communications, 13

FEA (finite element analysis), 175

analysis procedure in, 178 “179

common problems in, 182

definition of, 362

input to models in, 180

outputs from, 180 “181

procedures in, 178

solution procedure in, 179 “180

techniques in, 182

types of, 176 “177

Feasibility, 362

Feasible designs, 183 “184

Feature of size , 522

Features, 112, 522

Federal Database Finder, 147

Federal depository libraries, 147

Federal Reserve banks, 147

Feedback, 30 “31

descriptive, 31, 33

loops , 30 “31

negative, 35

positive, 35

systems, 31, 35

Feeders, 207

Feelings, and change management, 127

Fiber optical tests, 530

Fiber sensors, 218

Field performance data, 487

Field service reports, 279

FIFO (first-in first-out) method), 683

Finance, as measure of quality cost, 495

Financial analysis, 704 “709

breakeven analysis, 704 “705

contribution margin analysis, 706

EOQ (Economic Order Quantity) model, 707

IRR (internal rate of return) method, 709 “710

modified duPont system, 704 “705

NPV (net present value) method, 709

price-volume variance analysis, 707

return on investment analysis, 708 “709

ROI (return on investment), 708 “709

Financial assets; see also assets

Financial benchmarking, 157

Financial forecasting, 688

Financial leverage

in annual reports, 672

and earnings, 692

in financial comparison, 131

in modified duPont formula, 704 “705

in rating bonds , 695

in rating stocks, 697

ratios, 692

Financial management rate of return (FMRR), 709 “710

Financial planning, 710 “712

Financial position, statement of. see balance sheets

Financial rating companies, 695

Financial rating systems, 695

bond rating companies, 695 “696

commercial credit ratings, 698

Financial ratios, 145

Financial reports, 146, 664

accountants ' report, 671

annual reports, 671

audited , 671

balance sheets, 664 “665

Financial statement analysis, 688

Finished product inspection, 528

Finite element analysis. see FEA

Finite elements, 175 “176

Firm, theory of, 661 “662

First-in first-out (FIFO) method, 683

Fishbone diagram, 134, 348, 373

Fixed assets, 665 “666

accumulated depreciation of, 684

in cash flow analysis, 701

in financial comparison, 131

as noncurrent assets, 667

Fixed burden costs, 569

Fixed costs, 569

in breakeven analysis, 704 “705

in contribution margin analysis, 706

definition of, 703

Fixed-sample tests, 314

using binomial distribution, 315 “316

using exponential distribution, 318 “320

using hypergeometric distribution, 315

using Poisson distribution, 316

using Weibull and normal distributions, 320

Florida Power and Light, 143

Flow charts , 61 “63, 153 “154

Fluid mechanics, 177

FMEA (failure modes and effects analysis), 223 “224

action plans in, 253 “258

in benchmarking, 134

benefits of, 226

common problems in, 260 “262

in core engineering process, 299

definition of, 224, 362

design FMEA. see design FMEA

design/process controls in, 250

in design reviews, 467

detection rating in, 250

in DFM/DFA (design for manufacturability/assembly), 199

in DFSS (design for six sigma), 716, 721

failure mode analysis in, 240 “242

forms, 235 “238

vs. FTA (fault tree analysis), 469

function concepts in, 53, 64 “68

getting started with, 228 “235

history of, 226 “227

initiating, 227 “228

learning stages in, 262

machinery. see machinery FMEA

in problem solving, 225 “226

process. see process FMEA

in quality lever, 227

scopes of, 236

steps of, 469

transferring causes and occurrences to forms, 250

transferring current controls and detection to forms, 254

transferring RPN to forms, 256

transferring severity and classification to forms, 248

types of, 224 “225

typical body, 237

typical header, 236

FMRR (financial management rate of return), 709 “710

Focus groups, 131, 147

Footnotes, in balance sheets, 670

Force, 527

Force field analysis, 128 “129

Ford Motor Co., 41, 169, 203, 296 “297

Forecasts

in expanded partnering, 17

financial, 688

as measure of quality cost, 495

sales forecasting, 710

technology forecasting, 156 “157

Forgetfulness, 210

Forging, 204

Fork lifts, 207

Formal qualification review, 466

Four-level factors, 389

FRACAS (failure reporting, analysis, and corrective action system), 341, 352, 362

F ratio statistical test, 408

Freedom of Information Act, 147

Free-state conditions, 522

Freight costs, 570

Frequency distributions, 170

Friction, 179, 294

FTA (fault tree analysis), 299

definition of, 362

in design FMEA, 267

in determining causes of failures, 248

vs. FMEA (failure modes and effects analysis), 469

in QFD (quality function deployment), 725

in R&M (reliability and maintainability), 348, 355

seven-step approach to, 469 “470

Fuji-Xerox, 143

Functional analysis, 156

Functional analysis system technique (FAST), 567, 577 “580, 712

Functional area costs, 573

Functional benchmarking, 122, 123

Functional requirements, 541 “543

Function journals, 145

Functions, 52 “53, 574

alternatives to, 558 “559

analysis and evaluation, 567 “568, 575 “580

basic functions, 574 “575

and costs, 580

definition of, 52, 230

of designs, 264

determining, 567, 573 “574

developing, 238

diagrams, 55 “56

as dimension of product quality, 113

enhancing, 58 “59

essential, 58 “59

evaluating, 580 “582

failure modes, 66 “67

in FMEA (failure modes and effects analysis), 64 “68, 230

objective, 183

organizing, 239 “240

penalty, 185

in product flow diagrams, 56 “61

of products, 264

in QFD (quality function deployment), 64 “68

secondary, 575

task, 58 “59

terminus, 66 “67

tree structure, 239 “240

types of, 264

in VA (Value Analysis), 64 “68

in value analysis, 557

in value control, 567 “568, 573 “574

values, 581 “582

Function tree process, 239 “240

Functives, 55 “56

Funds

in annual reports, 671

in balance sheets, 669

discretionary, 700

sources of, 661, 669

use of, 670