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

Chapter 2: Customer Understanding

Figure 2.1: Paper pencil assembly.

Figure 2.2: Function diagram for a mechanical pencil.

Figure 2.3: Ten symbols for process flow charting.

Figure 2.4: Process flow for complaint handling.

Figure 2.5: Kano model framework.

Figure 2.6: Basic quality depicted in the Kano model.

Figure 2.7: Performance quality depicted in the Kano model.

Figure 2.8: Excitement quality depicted in the Kano model.

Figure 2.9: Excitement quality depicted over time in the Kano model.

Figure 2.10: A typical House of Quality matrix.

Figure 2.11: The initial "what" of the customer.

Figure 2.12: The iterative process of "what" to "how."

Figure 2.13: The relationship matrix.

Figure 2.14: The conversion of "how" to "how much."

Figure 2.15: The flow of information in the process of developing the final "House of Quality."

Figure 2.16: Alternative method of calculating importance.

Figure 2.17: The development of QFD.

Chapter 3: Benchmarking

Figure 3.1: The benchmarking continuum process.

Chapter 5: Design for Manufacturability/Assembly (DFM/DFA or DFMA)

Figure 5.1: Trade-off relationships between program objectives (balance design).

Figure 5.2: Sequential approach.

Figure 5.3: Simultaneous approach.

Figure 5.4: Tomorrow's approach ... if not today's.

Figure 5.5: The product development map/guide.

Figure 5.6: Manufacturing system schematic.

Figure 5.7: Approaches to mistake proofing.

Figure 5.8: Major inspection techniques.

Figure 5.9: Functions of mistake-proofing devices.

Chapter 6: Failure Mode and Effect Analysis (FMEA)

Figure 6.1: Types of FMEA.

Figure 6.2: Payback effort.

Figure 6.3: Kano model.

Figure 6.4: A Pugh matrix shaving with a razor .

Figure 6.5: Scope for DFMEA braking system.

Figure 6.6: Scope for PFMEA printed circuit board screen printing process.

Figure 6.7: Typical FMEA header.

Figure 6.8: Typical FMEA body.

Figure 6.9: Function tree process.

Figure 6.10: Example of ballpoint pen.

Figure 6.11: FMEA body.

Figure 6.12: Transferring the failure modes to the FMEA form.

Figure 6.13: Transferring severity and classification to the FMEA form.

Figure 6.14: Transferring causes and occurrences to the FMEA form.

Figure 6.15: Transferring current controls and detection to the FMEA form.

Figure 6.16: Area chart.

Figure 6.17: Transferring the RPN to the FMEA form.

Figure 6.18: Action plans and results analysis.

Figure 6.19: Transferring action plans and action results on the FMEA form.

Figure 6.20: FMEA linkages.

Figure 6.21: The learning stages.

Figure 6.22: Pen assembly process.

Chapter 7: Reliability

Figure 7.1: Bathtub curve.

Figure 7.2: A series block diagram.

Figure 7.3: A parallel reliability block diagram.

Figure 7.4: A complex reliability block diagram.

Figure 7.5: The Weibull distribution for the example.

Figure 7.6: Control factors and noise interactions.

Figure 7.7: An example of a parameter design in reliability usage.

Chapter 9: Design of Experiments

Figure 9.1: An example of a partially completed fishbone diagram.

Figure 9.2: An example of interaction.

Figure 9.3: Example of cause-and-effect diagram.

Figure 9.4: Plots of averages (higher responses are better).

Figure 9.5: A linear example of a process with several factors.

Figure 9.6: Contrasts shown in a graphical presentation.

Figure 9.7: First round testing.

Figure 9.8: Second round testing.

Figure 9.9: Linear graph for L4.

Figure 9.10: The orthogonal array (OA), linear graph (LG), and column interaction for L9.

Figure 9.11: Three-level factors in a L8 array.

Figure 9.12: Traditional approach.

Figure 9.13: Nominal the best.

Figure 9.14: Smaller the better.

Figure 9.15: Larger the better.

Figure 9.16: A comparison of C _pk and loss function.

Figure 9.17: Plots of averages (higher responses are better).

Figure 9.18: ANOVA decomposition of multi-level factors.

Figure 9.19: Factors not linear.

Figure 9.20: Plots of the average standard deviation by factor level.

Figure 9.21: Factor effects.

Figure 9.22: Factor effects.

Chapter 10: Miscellaneous Topics Methodologies

Figure 10.1: Quality cost The quality control system.

Figure 10.2: Costs.

Chapter 11: Innovation Techniques Used in Design for Six Sigma (DFSS)

Figure 11.1: A typical branching using signal flow graph.

Figure 11.2: A simple example with signal flow graph.

Figure 11.3: A hypothetical design process.

Figure 11.4: The graph transmission.

Figure 11.5: First few terms of the probability.

Figure 11.6: The effect of a self loop.

Figure 11.7: Node absorption .

Figure 11.8: Order of design matrix showing functional coupling between FRs and DPs.

Figure 11.9: Relationship of axiomatic design framework and other tools.

Chapter 12: Value Analysis/Engineering

Figure 12.1: Relationship of savings potential to time.

Figure 12.2: Project identification sheet.

Figure 12.3: Cost visibility sheet.

Figure 12.4: Cost function worksheet.

Figure 12.5: A form that may be used to direct effort.

Figure 12.6: Second step in the FAST diagram block process.

Figure 12.7: A partial cost function FAST diagram.

Chapter 15: Fundamentals of Finance and Accounting for Champions, Master Blacks, and Black Belts

Figure 15.1: Life cycle of a typical company or product.

Figure 15.2: A pictorial approach of DuPont's formula.

Figure 15.3: Breakeven analysis.

Chapter 16: Closing Thoughts About Design for Six Sigma (DFSS)

Figure 16.1: The DFSS model.