Black Belt add on with DFSS Green Belt

///Black Belt add on with DFSS Green Belt
Black Belt add on with DFSS Green Belt2019-09-02T16:43:47+01:00

Training information

Design for Six Sigma (DFSS) means to design products and processes that they cover all of the requirements at the right beginning and to avoid problem solving and fire fighting after start of production. DFSS is goal oriented and causal in order to develop products and/or processes in whole or in part. DFSS aligns the design tasks with methodology and data analytics.

The objective is to develop products and/or processes as prompted all external and internal customers and to ensure a smooth running of a new series. The technical and methodological angles of DFSS are interactive with a required target costing and depending on project specific challenges Data Mining is integrated as well.

Duration:5 days (from 9.00 to 17.00 Uhr)
Cost excl. VAT
QualificationCertificate of attendance for “Design for Six Sigma Black Belt”
Minimum participants:3
PrerequisitesEach participant must have a notebook with the software Microsoft® Excel 2003, MINITAB® from R14 or younger and Adobe® Reader® ab 7.0 . The Software MINITAB® can be provided via us.
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  • You will achieve a fundamental understanding about the DFSS methodology for product- and process design and you will be able to apply it in your company or you can support design engineers
  • You are able to design also complex products or processes according to DFSS.
  • You are aware of the necessity and challenge for an integration of DFSS into the product development process (PEP) of your company

Target group:

Product- and Process design engineers, scientists, engineers, R&D, Engineering, production and Quality management

Training contents:

Our training is following the DMADV cycle. There are several other DFSS models but our opinion is that it’s not relevant. The key issue is to start a root cause design and deliver it as required proven by data. The following contents belong to DFSS and several will be just summarized and reviewed (base of DFSS GB) but others will be discussed more detailed (DFSS BB Level).

In this phase a design project will be defined and documented:
What are the key requirements and expectations on this DFSS project, what should be designed and why?

  • Create a Development Strategy
  • Set targets and product idea
  • Develop the Business case
  • Plan and define a Project plan
  • Define ressources and gates
  • Create an evaluation
  • Create a communication plan
  • Define/ fix target costs
In this phase all relevant requirements from all customers are collected segmented, compacted and prioritised. These informations are the base for a design of alternative concepts.

  • Collect and compile the customer’s requirements
  • Prioritise and translate the requirements into CTS`s (specific and measurable customer requirements), specify target values and tolerances if possible
  • Transform CTS’s into functional requirements
  • Develop alternative design concepts
  • Introduction into the creative toolbox
  • Basics of TRIZ
The different design concepts generated are to be analysed with respect to the criteria which would cause trouble later on during production if not satisfying.

  • Identify performance and functionality, details of statistical possibilities
  • Calculate the design complexity
  • Estimate risks (based on data)
  • Determine costs
  • Identify and assess critical elements in design and construction
  • Analyze essential critical couplings, judgement of a decoupled or a coupled design
  • Trimming of designs
  • Develop a concept selection matrix and select the best concept
  • Pugh concept selection
  • Optimise and finalise the concept
  • Create specifications
After a selection of the best concept the detailed design will be initiated, for a product and / or for one or more processes (depending on the project contents).

  • Determination of all necessary product components
  • Evaluation of the relevant transfer functions (Y = f (x))
  • Optimal parameterizations and tolerance setting
  • Arithmetic and statistical tolerancing
  • Tolerancing and Monte Carlo simulation
  • Ensure the robustness of the design
  • Test/measurement and sampling strategy
  • Demonstrate a robust product design

There is a prosecution of the causal chain of DFSS into the process design and the elementary inputs are the product specification and all further requirements existing. If it is necessary ti start a new design of any process then it needs to be started.

  • Determine the required process capabilities and comparison with the existing processes
  • Systematic generation of process design concepts
  • Analysis of the concepts related to
  • Functionality / performance
  • Complexity
  • Risks
  • Costs
  • Malfunctions
  • Elementary couplings
  • Optimization and finalization of the best concept
  • Axiomatic process design, detailed investigation of decoupled and coupled designs
  • Calculation of the information content of a process design
  • Determination of all necessary process components
  • Design Score Cards 3+4
  • Process Modelling (DoE or Data Mining)
  • Evaluation of the relevant transfer functions (y = f (x))
  • Evaluation of optimal parameters
  • Development of the necessary control concept
  • Machine – and Process Qualification
  • QFD – House of Quality (3+4)
  • Process FMEA with data based interfaces
  • Functional analysis for process designs
  • Trimming of process designs
  • Development of hypothetic process transfer functions
  • Evaluation of the relevant process transfer functions (Y=f(x))
  • Design of a process control concept suitable for the future production
  • Measurement and sampling strategy, Basic-Roadmap
  • Review of the Roadmap for Measurement System Analysis (MSA)
This is last phase and the finalization of the design project. The whole project goals are compared with all of the achieved performance of the design and it is a final review before hand over to production:

  • Evaluation/review the product – and process performance
  • Demonstrate and proof life cycle and reliability
  • Statistical analysis of life cycle and reliability
  • Evaluation/review of the purchased part and supplier capabilities
  • Review of the development order
  • Finalize and project and production documentation
  • Delivery of the product and/or process design to production
  • R&D handover on the base of appropriate agreed KPIs
  • Hand over to series production

Scope of services:

  • Detailed training documentation (in paper and as .pdf.-files)
  • Coaching of your project by an experienced Master Black Belt (limited)
  • Numerous data files, tools for exercises
  • Certificate “Design for Six Sigma Black Belt”
  • Free space for exchange and knowledge transfer