Black Belt add on with DFSS Green Belt

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)
Date	–
Venue	–
Cost excl. VAT	–
Qualification	Certificate of attendance for “Design for Six Sigma Black Belt”
Minimum participants:	3
Prerequisites	Each 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.
Print Description

Goal(s):

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).

DEFINE

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

MEASURE

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

ANALYZE

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

DESIGN

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)

VERIFY

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

Gebhard Mayer

Managing Partner, Master Black Belt

Dipl. Eng. Gebhard Mayer has very intensive and longterm experiences in the Management of R&D, production, Quality and also Engineering. His spectrum of competencies contains many items from different industrial branches.
His main strenghts are a systematic way of working, paired with data ananalytics as well as root cause thinking and a visualization which is very important and helpful in complex projects.

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