Design For Six Sigma In Technology And Product Development

797 Pages·2002·4.849 MB·English

by  Clyde M. Creveling, Dave Antis,  Jeff Slutsky,

D F S S
ESIGN OR IX IGMA
In Technology and Product Development
Product
Development
Process
...what to do and when to do it. . .
Tools and Project
Best Management
Practices Methods
C. M. Creveling, J. L. Slutsky, and D. Antis, Jr.
Prentice Hall PTR
Upper Saddle River, New Jersey
www.phptr.com
Library of Congress Cataloging-in-Publication Data
Creveling, Clyde M.
Design for Six Sigma : in technology & product development / C.M. Creveling, J.L.
Slutsky & D. Antis.
p. cm.
Includes bibliographical references and index.
ISBN 0-13-009223-1
1. Quality control--Statistical methods. 2. Experimental design. I. Slutsky, Jeff, 1956-
II. Antis, D. (Dave) III. Title.
TS156 .C74 2003
658.5'62dc21
2002027435
Publisher:Bernard Goodwin
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We would like to dedicate this book to our families.
For Skip Creveling
Kathy and Neil Creveling
For Jeff Slutsky
Ann, Alison, and Jason
For Dave Antis
Denise, Aaron, Blake, Jared, and Shayla Antis
Without their patience and support, this book would have been much thinner.
This page intentionally left blank
Brief Contents
Foreword xv
Preface xvii
Acknowledgments xxvii
PARTI Introduction to Organizational Leadership,Financial Performance,
and Value Management Using Design For Six Sigma 1
CHAPTER 1 The Role of Executive and Management Leadership in Design
For Six Sigma 3
CHAPTER 2 Measuring Financial Results from DFSS Programs and Projects 13
CHAPTER 3 Managing Value with Design For Six Sigma 29
PARTII Introduction to the Major Processes Used in Design For Six Sigma
in Technology and Product Development 45
CHAPTER 4 Management of Product Development Cycle-Time 47
CHAPTER 5 Technology Development Using Design For Six Sigma 71
CHAPTER 6 Product Design Using Design For Six Sigma 111
CHAPTER 7 System Architecting,Engineering,and Integration Using Design
For Six Sigma 177
PARTIII Introduction to the Use of Critical Parameter Management in Design
For Six Sigma in Technology and Product Development 249
CHAPTER 8 Introduction to Critical Parameter Management 251
CHAPTER 9 The Architecture of the Critical Parameter Management Process 257
CHAPTER 10 The Process of Critical Parameter Management
in Product Development 265
CHAPTER 11 The Tools and Best Practices of Critical Parameter Management 309
CHAPTER 12 Metrics for Engineering and Project Management Within CPM 321
CHAPTER 13 Data Acquisition and Database Architectures in CPM 331
v
vi Brief Contents
PARTIV Tools and Best Practices for Invention,Innovation,and
Concept Development 337
CHAPTER 14 Gathering and Processing the Voice of the Customer:Customer
Interviewing and the KJ Method 341
CHAPTER 15 Quality Function Deployment:The Houses of Quality 361
CHAPTER 16 Concept Generation and Design for xMethods 381
CHAPTER 17 The Pugh Concept Evaluation and Selection Process 399
CHAPTER 18 Modeling:Ideal/Transfer Functions,Robustness Additive Models,
and the Variance Model 411
PARTV Tools and Best Practices for Design Development 435
CHAPTER 19 Design Failure Modes and Effects Analysis 437
CHAPTER 20 Reliability Prediction 449
CHAPTER 21 Introduction to Descriptive Statistics 471
CHAPTER 22 Introduction to Inferential Statistics 479
CHAPTER 23 Measurement Systems Analysis 495
CHAPTER 24 Capability Studies 507
CHAPTER 25 Multi-Vari Studies 519
CHAPTER 26 Regression 529
CHAPTER 27 Design of Experiments 549
PARTVI Tools and Best Practices for Optimization 569
CHAPTER 28 Taguchi Methods for Robust Design 571
CHAPTER 29 Response Surface Methods 601
CHAPTER 30 Optimization Methods 615
PARTVII Tools and Best Practices for Verifying Capability 629
CHAPTER 31 Analytical Tolerance Design 631
CHAPTER 32 Empirical Tolerance Design 671
CHAPTER 33 Reliability Evaluation 687
CHAPTER 34 Statistical Process Control 707
EPILOGUE Linking Design to Operations 723
APPENDIX A Design For Six Sigma Abbreviations 729
APPENDIX B Glossary 731
INDEX 751
Contents
Foreword xv
Preface xvii
Acknowledgments xxvii
PARTI Introduction to Organizational Leadership,Financial Performance,
and Value Management Using Design For Six Sigma 1
CHAPTER 1 The Role of Executive and Management Leadership in Design
For Six Sigma 3
Leadership Focus on Product Development as Key Business Process 3
The Strategic View of Top-Line Growth 8
Enabling Your Product Development Process to Have the Ability to Produce the
Right Data, Deliverables, and Measures of Risk within the Context of
Your Phase/Gate Structure 10
Executive Commitment to Driving Culture Change 11
Summary 11
References 12
CHAPTER 2 Measuring Financial Results from DFSS Programs and Projects 13
ACase Study 13
Deploying the Voice of the Customer 14
DFSS Project Execution Efficiency 16
Production Waste Minimization 18
Pricing and Business Risk 24
CHAPTER 3 Managing Value with Design For Six Sigma 29
Extracting Value 29
Value as a Formula 31
Measuring Value in the Marketplace 33
Identifying the Purposes of Design 36
Design Based on the Voice of the Customer 37
Putting Concept Engineering to Work 38
References 44
vii
viii Contents
PARTII Introduction to the Major Processes Used in Design For Six Sigma
in Technology and Product Development 45
CHAPTER 4 Management of Product Development Cycle-Time 47
The Product Development Process Capability Index 48
Product Development Process 50
Project Management 58
The Power of PERTCharts 60
References 70
CHAPTER 5 Technology Development Using Design For Six Sigma 71
The I2DOVRoadmap: Applying a Phase/Gate Approach to Technology
Development 72
I2DOVand Critical Parameter Management During the Phases and Gates
of Technology Development 77
I2DOVPhase 1: Invention and Innovation 78
I2DOVPhase 2: Develop Technology Concept Definition, Stabilization, and
Functional Modeling 87
I2DOVPhase 3: Optimization of the Robustness of the Subsystem Technologies 92
I2DOVPhase 4: Certification of the Platform or Subsystem Technologies 101
References 110
CHAPTER 6 Product Design Using Design For Six Sigma 111
An Introduction to Phases and Gates 112
Preparing for Product Commercialization 113
Defining a Generic Product Commercialization Process Using CDOV
Roadmap 114
The CDOVProcess and Critical Parameter Management During the Phases and
Gates of Product Commercialization 117
CDOVPhase 2: Subsystem Concept and Design Development 133
CDOVPhase 3A: Optimizing Subsystems 150
CDOVPhase 3B: System Integration 160
CDOVPhase 4A: Verification of Product Design Functionality 165
CDOVPhase 4B: Verification of Production 171
References 176
CHAPTER 7 System Architecting,Engineering,and Integration Using Design
For Six Sigma 177
Phase 1: System Concept Development 179
Phase 2: Subsystem, Subassembly, Component, and Manufacturing Concept
Design 196
Phase 3A: Subsystem Robustness Optimization 210
Contents ix
Phase 3B: System Integration 219
Phase 4A: Final Product Design Certification 231
Phase 4B: Production Verification 241
References 247
PARTIII Introduction to the Use of Critical Parameter Management in Design
For Six Sigma in Technology and Product Development 249
CHAPTER 8 Introduction to Critical Parameter Management 251
Winning Strategies 251
Focus on System Performance 252
Data-Driven Process 253
The Best of Best Practices 256
Reference 256
CHAPTER 9 The Architecture of the Critical Parameter Management Process 257
Who Constructs the CPM Process? 258
Timing Structure of the CPM Process: Where and When Does CPM Begin? 258
What Are the Uses of CPM? 259
Reference 263
CHAPTER 10 The Process of Critical Parameter Management
in Product Development 265
Definitions of Terms for Critical Parameter Management 268
Critical Parameter Management in Technology Development and Product
Design: Phase 1 271
Phase 2 in Technology Development or Product Design 276
Phases 3 and 4: Stress Testing and Integration 302
Capability Summaries and the Capability Growth Index 307
CHAPTER 11 The Tools and Best Practices of Critical Parameter Management 309
The Rewards of Deploying Proven Tools and Best Practices 310
Critical Parameter Management Best Practices for Technology
Development 312
Critical Parameter Management Best Practices for Product
Commercialization 315
CHAPTER 12 Metrics for Engineering and Project Management Within CPM 321
Key CPM Metrics 322
Statistical Metrics of CPM 326
The Capability Growth Index and the Phases and Gates of Technology
Development and Product Commercialization 329
CHAPTER 13 Data Acquisition and Database Architectures in CPM 331
Instrumentation, Data Acquisition, and Analysis in CPM 331
Databases: Architectures and Use in CPM 335
References 336