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

Introduction Understanding the Six Sigma Philosophy

Table I.1: Probability of a Completely Conforming Product

Chapter 1: Prerequisites to Design for Six Sigma (DFSS)

Table 1.1: Customer/Supplier Expanded Partnering Interface Meetings

Table 1.2: A Typical Questionnaire

Table 1.3: A General Questionnaire

Chapter 2: Customer Understanding

Table 2.1: Characteristic Matrix for a Machining Process

Table 2.2: Benefits of Improved Total Development Process

Table 2.3: Stimuli Descriptions and Respondent Rankings for Conjoint Analysis of Industrial Cleanser

Table 2.4: Average Ranks and Deviations for Respondents 1 and 2

Table 2.5: Estimated Part-Worths and Factor Importance for Respondents 1 and 2

Table 2.6: Predicted Part-Worth Totals and Comparison of Actual and Estimated Preference Rankings

Chapter 3: Benchmarking

Table 3.1: A Typical Assessment Instrument

Table 3.2: An Example of Cash Flow and Present Value

Table 3.3: Benchmark Project Evaluations

Chapter 4: Simulation

Table 4.1: Simulated Samples of 20 Performance Time Values for Operations A and B

Table 4.2: Simulated Operation of the Two-Station Assembly Line when Operation A Precedes Operation B

Table 4.3: Simulated Operation of the Two-Station Assembly Line when Operation B Precedes Operation A

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

Table 5.1: Customer Attributes for a Car Door

Table 5.2: Relative Importance of Weights

Table 5.3: Customer's Evaluations of Competitive Products

Table 5.4: Examples of Mistakes and Defects

Chapter 6: Failure Mode and Effect Analysis (FMEA)

Table 6.1: DFMEA Severity Rating

Table 6.2: PFMEA Severity Rating

Table 6.3: DFMEA Occurrence Rating

Table 6.4: PFMEA Occurrence Rating

Table 6.5: DFMEA Detection Table

Table 6.6: PFMEA Detection Table

Table 6.7: Special Characteristics for Both Design and Process

Table 6.8: Manufacturing Process Control Matrix

Table 6.9: Machinery Guidelines for Severity, Occurrence, and Detection

Chapter 7: Reliability

Table 7.1: Failure Rates with Median Ranks

Table 7.2: Median Ranks

Table 7.3: Five Percent Rank Table

Table 7.4: Ninety-five Percent Rank Table

Table 7.5: Department of Defense Reliability and Maintainability Standards and Data Items

Chapter 8: Reliability and Maintainability

Table 8.1: Activities in the First Three Phases of the R&M Process

Table 8.2: Cost Comparison of Two Machines

Table 8.3: Thermal Calculation Values

Table 8.4: Guidelines for the Duane Model

Chapter 9: Design of Experiments

Table 9.1: One Factor at a Time

Table 9.2: Test Numbers for Comparison

Table 9.3: The Group Runs Using DOE Configurations

Table 9.4: Comparisons Using DOE

Table 9.5: Comparison of the Two Means

Table 9.6: The Test Matrix for the Seven Factors

Table 9.7: Test Results

Table 9.8: An Example of Contrasts

Table 9.9: L4 Setup

Table 9.10: The L8 Interaction Table

Table 9.11: An L9 with a Two-Level Column

Table 9.12: Combination Method

Table 9.13: Modified L8 Array

Table 9.14: An L8 with an L4 Outer Array

Table 9.15: Recommended Factor Assignment by Column

Table 9.16: Formulas for Calculating S/N

Table 9.17: Concerns with NTB S/N Ratio

Table 9.18: L8 with Test Results

Table 9.19: ANOVA Table

Table 9.20: Higher Order Relationships

Table 9.21: Inner OA (L8) with Outer OA (L4) and Test Results

Table 9.22: The STB ANOVA Table

Table 9.23: The LTB ANOVA Table

Table 9.24: The NTB ANOVA Table

Table 9.25: Raw Data ANOVA Table

Table 9.26: Combination Design

Table 9.27: L9 OA with Test Results

Table 9.28: ANOVA Table

Table 9.29: Second Run of ANOVA

Table 9.30: L8 with Test Results and S/N Values

Table 9.31: ANOVA Table for Data from Table 9.30

Table 9.32: Significant Figures from Table 9.31

Table 9.33: Observed Versus Cumulative Frequency

Table 9.34: Attribute Test Setup and Results

Table 9.35: ANOVA Table (for Cumulative Frequency)

Table 9.36: The Effect of the Significant Factors

Table 9.37: Rate of Occurrence at the Optimum Settings

Table 9.38: Door Closing Effort: Test Setup and Results

Table 9.39: ANOVA Table for Door Closing Effort

Table 9.40: The Effects of the Door Closing Effort

Table 9.41: Rate of Occurrence at the Optimum Settings

Table 9.42: OA and Test Setup and Results

Table 9.43: ANOVA for the Raw Data

Table 9.44: ANOVA Table for the NTB S/N Ratios

Table 9.45: Typical ANOVA Table Setup

Table 9.46: L4 OA with Test Results

Table 9.47: ANOVA Table Raw Data

Level Averages NTB S/N Data

Table 9.48: ANOVA Table (S/N Ratio Used as Raw Data)

Table 9.49: Level Averages Raw Data

Table 9.50: OA Setup and Test Results for Example 2

ANOVA Table (Raw Data)

Table 9.51: ANOVA Table (S/N Ratio Used as Raw Data)

Level Averages

Table 9.52: Transformed Data

Table 9.53: ANOVA Table for the Transformed Data

Table 9.54: Components and Their Levels

Table 9.55: L8 Inner OA with L8 Outer OA and Test Results

Actual Test Values of A

Table 9.56: ANOVA Table (NTB) and Level Averages for the Most Significant Factors

Table 9.57: Variation Runs Using Recommended Factor Target Values

Table 9.58: Calculated Response Variance

Table 9.59: Cost of Reducing Tolerances

Table 9.60: The Impact of Tightening the Tolerance

Table 9.61: Reduction of 20% in the Tolerance Limits of Component A

Table 9.62: Reduction of Tolerance Limits for Component D

Table 9.63: Reduction of Tolerance Limits for Component C

Table 9.64: L8 OA used for the Confirmation Runs with the Levels Set, Test Setup, ANOVA Table, and Level Averages

ANOVA Table

Table 9.65: Response Variance

Chapter 10: Miscellaneous Topics Methodologies

Table 10.1: Design Review Objectives

Table 10.2: Design Review Checklist

Table 10.3: Comparison Between Traditional and Concurrent Engineering

Table 10.4: Typical Monthly Quality Cost Report (Values in Thousands of Dollars)

Table 10.5: Prevention Costs

Table 10.6: Appraisal Costs

Table 10.7: Internal Failure Costs

Table 10.8: External Failure Costs

Table 10.9: Seven-Step Process Redesign Model

Table 10.10: GD&T Characteristics and Symbols

Chapter 12: Value Analysis/Engineering

Table 12.1: Project Identification Checklist

Table 12.2: Idea Needlers or Thought Stimulators

Table 12.3: The Worksheet for Setting the List

Table 12.4: Evolution Summary

Table 12.5: Ranking and Weighting

Table 12.6: Criteria Affecting Car Purchase XXXX Paired Comparison

Table 12.7: Criteria Weighing

Table 12.8: Criteria Comparison

Table 12.9: Criteria Weight Comparison Completed Matrix

Chapter 13: Project Management (PM)

Table 13.1: Key Integrative Processes

Table 13.2: The Characteristics of the DFSS Implementation Model Using Project Management

Table 13.3: The Process of Six Sigma/DFSS Implementation Using Project Management

Chapter 14: Limited Mathematical Background for Design for Six Sigma (DFSS)

Table 14.1: Possibilities of Selecting a DFSS Problem

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

Table 15.1: A Summary of Debits and Credits

Table 15.2: Summary of Normal Debit/Credit Balances

Table 15.3: The Z Score