Black Belt without prior knowledge

///Black Belt without prior knowledge
Black Belt without prior knowledge2019-09-02T16:40:47+00:00

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:25 days (from 9.00 to 17.00 Uhr)
Date
Venue
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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Goal(s):

  • You will know the requirements for a successful implementation of the Six Sigma -Methodology in your company. You are ware that Six Sigma will not be chosen in every problem situation and you will be able to decide in which situations it’s needed.
  • You realise that Six Sigma is definitely necessary if you have an important process problem and the root cause is not known, and you experience that such systematic projects are much more successful than the traditional way of working which consists of „Try & Error“ mostly.
  • You will have learnt all of the important tools and methods and you’re able to apply them in a Six Sigma Black Belt Project, also outside of your direct environment of responsibility.
  • You can handle standardised tools of Project management in order to manage and guide your Black Belt Project team successfully. You will be able to close a project within a given time frame.
  • You will be able to achieve all of the goals which have been defined for your Black Belt Project and the expected Benefit will be delivered. This will be possible because you have investigated the significant root cause and developed a causal chain from the top project KPI to the true causes.
  • You will learn tools for modern data analysis and you will be able to apply them in different business situations in order to solve problems. You will get also an overview about some possibilities for a usage of data that are stored in process control systems or if you have an access to historical data.
  • 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 more 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 but also Marketing and sales and other branches like service companies

Training contents:

Each candidate will select a Six Sigma -Project in his company and start to work on it parallel to the training, already.. It is also possible that 2 candidates take a project if the belong to the same company. Selection can be supported by the trainer and he may give some advices regarding tool application.. The trainer takes also the role of a Coach and you may ask him for a support during this period. This Coaching is limited to smaller topics but if you need additional help, then we can arrange an intensive Coaching, of course. You should be aware that there are many potential obstacles and risks along such complex projects and if you can’t receive help because lack of coaching then the probability for a collapse of the project will increase.

Introduction into the Six Sigma DMAIC

The goal of the Define phase ist o get a 100% concrete understanding of the project and the existing process situation in the business. Also the scope oft he project must be defined realistic as well as the goal(s) which must be achieved.. The Project charter fixes all of the general conditions and takes care of all relevant aspects. The project charter can be compared with a contract. Important tools are:

  • Project Charter
  • Project KPI
  • Six Sigma –Project organisation and Management
  • Project risk analysis
  • Process diagram (SIPOC, Supplier, Input, Process, Output, Customer)
  • VoC, Voice of customer
  • Tools for prioritisation (C&E Matrix, Pareto)
The second stage of a Six Sigma Project contains data collection in order to calculate the actual process capability.
Important tools are:

  • Measurement variables and data type
  • Basics of statistics , KPI‘s
  • Basic requirements for reliable and representative data collection
  • Complete roadmap for Measurement system analysis (Gage analysis) , procedure 1, 2 and 3 inclusive attribute agreement analysis and destroying test procedures
  • Development of suitable sampling strategies – complete roadmap
  • Process capability analysis for continuous and discrete items – complete roadmap
  • Multi vari analysis
  • Modern tools for data analysis with Case Studies
The Analyze-Phase contains a systematic process analysis and it’s the starting point for a root cause detection. It takes the existing process performance as an input and continuous the development of causal chain. All of the potential causes will be investigated and concrete hypothesis will be developed. Then trials and measurements will be initiated in order to prove the hypothesis. The whole root cause will become transparent by data analysis and graphical ones, too. Finally the responsible causes will be known.
Important tools are :

  • Methods for process visualizations
  • Risk analysis (Data based FMEA)
  • Ishikawa
  • XY-Matrix
  • Development of hypothesis and planning of trials and measurements
  • Detection of patterns inside of data
  • Hypothesis tests
  • Regression analysis – complete roadmap
  • Analysis of variance – complete roadmap
  • Design of Experiments (DoE) – complete roadmap with Screening experiments, Response surface designs, D-optimal Designs as well as the interface to Data Mining
  • Determination of transfer functions in the sense of Y=f(x)
  • Simulations
In the Improve phase the process will be modified in a manner that the Output(s) meet all of the customer requirements.
Important tools are:

  • Generation of solutions
  • Tools for a systematic selection of the best solution
  • Implementation of a solution
  • Cost-Benefit-Analysis
  • Pilot phase
  • Before / after – comparison
In the Control phase there is are developed and implemented a suitable process control concept to avoid that it becomes worse again
Important tools are:

  • Development of a control plan
  • SPC-Control charts,(Design,application, interpretation)
  • Process Controlling
  • Project closure

Introduction into Design for Six Sigma

Our DFSS approach is following the DMADV cycle and 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.

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 der Roadmap zur Messsystemanalyse (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 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