六西格玛设计和可靠性设计

Design for SixSigma(DFSS)
& Design for Reliability(DFR) 六西格玛设计和可靠性设计

The Journey
1998 – Seagate adopts Six Sigma defect reduction,
cost savings
1999 – Lean in Manufacturing &
Supply Chain
Intro BE July 2010
2001 – DFSS in Product & Process
Development
Page 2

DFSS in the Beginning
Iterative
Use of historical requests Test and re-test
Short term estimates Isolated CTQ optimization
Predictive
Requirements hierarchy Model building
Long term estimates System optimization
Initial Approach:
Top down Educate the masses in design centers -> “DFSS Certified”
• DFSS Foundation – 2 weeks of Statistics • DFSS Project – Systems Engineering – 3 days Train the suppliers and factory BrB/BB/MBBs in DFSS
Intro BE July 2010
Page 3

What Is Design for Six Sigma?
Design for Six Sigma (DFSS):
• Allows us to set “need-based” requirements for CTQs and to evaluate our capability to meet those requirements.
• Is a process that focuses on predictive product design. • Emphasizes the use of statistical methods to predict
product quality early in the design process.
• Is a complement to good engineering/decision making practices.
Intro BE July 2010
Page 4

Six Sigma Improvement Methodology
1 A
Define
YES
2
NO
1.
Measure
Identify
2.
YES
3
NO
Analyze
Design
3.
Optimize
YES
4
NO
Improve
5
YES
A
4.
NO
Validate
5.
Control
A high level Business need is identified(CTQ gap)
Does a Current Business Process/Product exist to address the gap
Are the Processes/Products that support your key outputs optimized but still not capable of meeting customer requirements?
Is the solution or part of the solution a new process, product, or service.
Does the capability of one or more KPIV need to be improved to optimize KPOV?
Intro BE July 2010
Page 5

Statistical Design
Identify Design
Optimize Validate
Intro BE July 2010
Identify Customer Requirements
Translate Into Critical To Quality (CTQ) Measures and Key Process/Product Output Variable (KPOV) Limits
Formulate Designs/Concepts//Solutions
Validate The Measurement Systems Evaluate Designs
For Each Top Level CTQ, Identify Key Product/Process Input Variables (KPIV’s) Develop Transfer Functions Between Key
Input and Output Variables
Optimize Design
Perform Tradeoffs to Ensure that All CTQ’s Are Met
Not OK
Not OK OK
Exception Review
Determine Tolerances
Assess Process Capability to Achieve Critical Design Parameters and Meet CTQ Limits DFSS Scoring
Test & Validation
Perform Tradeoffs to Ensure that All CTQ’s Are Met
Not OK OK
Not OK Exception Review
Assess Performance, Failure Modes, Reliability and Risks
OK
Feasibility Point Tollgate
Not OK
Page 6
Breakthrough