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Design for Six Sigma: A Practical Approach through Innovation [Minkštas viršelis]

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(BASF Chemical, Quincy, Florida, USA), (Maryville University, St. Louis, USA)
  • Formatas: Paperback / softback, 357 pages, aukštis x plotis: 234x156 mm, weight: 539 g
  • Serija: Continuous Improvement Series
  • Išleidimo metai: 31-Mar-2021
  • Leidėjas: CRC Press
  • ISBN-10: 0367782898
  • ISBN-13: 9780367782894
Kitos knygos pagal šią temą:
Design for Six Sigma: A Practical Approach through InnovationDidesnis paveikslėlis
  • Formatas: Paperback / softback, 357 pages, aukštis x plotis: 234x156 mm, weight: 539 g
  • Serija: Continuous Improvement Series
  • Išleidimo metai: 31-Mar-2021
  • Leidėjas: CRC Press
  • ISBN-10: 0367782898
  • ISBN-13: 9780367782894
Kitos knygos pagal šią temą:
Pastovi nuoroda: https://www.kriso.lt/db/9780367782894.html
Raktažodžiai:
Design for Six Sigma (DFSS) is an innovative continuous improvement methodology for designing new products, processes, and services by integrating Lean and Six Sigma principles. This book will explain how the DFSS methodology is used to design robust products, processes, or services right the first time by using the voice of the customer to meet Six Sigma performance. Robust designs are insensitive to variation and provide consistent performance in the hands of the customer. DFSS is used to meet customer needs by understanding their requirements, considering current process capability, identifying and reducing gaps, and verifying predictions to develop a robust design.





This book offers:



















Methodology on how to implement DFSS in various industries













Practical examples of the use of DFSS













Sustainability utilizing Lean Six Sigma techniques and Lean product development













Innovative designs using DFSS with concept generation













Case studies for implementing the DFSS methodology











Design for Six Sigma (DFSS) enables organizations to develop innovative designs. In order to redesign an existing process or design a new process, the success is dependent on a rigorous process and methodology. DFSS ensures that there are minimal defects in the introduction of new products, processes, or services. The authors have compiled all of the tools necessary for implementation of a practical approach though innovation.

Recenzijos

"Very well written book in simple language that will help readers understand the related topics. The book covers related topics to implement Six Sigma. The case studies discussed by the authors will make understanding and adaptability of the subject by the professionals." Abdul Razzah Rumane, Construction Management, Sijjeel, Company, Kuwait

Preface xv
Authors xvii
Acknowledgments xxi
1 Design for Six Sigma Overview
1(8)
Six Sigma Review
2(1)
DFSS
3(3)
Comparison of Six Sigma and DFSS
6(1)
Conclusion
7(2)
2 History of Six Sigma
9(6)
Variation
11(2)
Conclusion
13(2)
3 Design for Six Sigma Methodology
15(8)
Conclusion
20(3)
4 Design for Six Sigma Culture and Organizational Readiness
23(18)
Organizational Change Management
23(6)
Resistance to Change
29(1)
Using Known Leaders to Challenge the Status Quo
30(1)
Communicating Change
30(4)
Conclusion
34(4)
Technical Design Review: Define and Measure Phases
38(3)
Technical Design Review
39(1)
Gate 1 Readiness: Define and Measure Phases
39(1)
Assessment of Risks
40(1)
5 Project Charter
41(6)
Introduction
41(1)
Project Charter Steps
41(1)
Risk Assessment
42(2)
Developing the Business Case
44(1)
Conclusion
45(2)
6 Balanced Scorecard
47(12)
Balanced Scorecard
47(2)
Key Performance Indicators
49(7)
Cost of Quality
50(1)
Financial Performance
51(1)
Process Performance
52(4)
Conclusion
56(3)
7 Benchmarking
59(8)
Best in Class
59(5)
Conclusion
64(3)
8 Project Management
67(18)
Why Projects Fail
69(1)
Management by Project
70(2)
Integrated Project Implementation
72(1)
Critical Factors for Project Success
73(1)
Project Organization
74(1)
Resource Allocation
74(1)
Project Scheduling
75(1)
Project Tracking and Reporting
75(1)
Project Control
75(1)
Project Termination
76(1)
Project Systems Implementation Outline
76(1)
Planning
76(1)
Organizing
77(1)
Scheduling (Resource Allocation)
78(1)
Control (Tracking, Reporting, and Correction)
78(1)
Termination (Close or Phase-Out)
79(1)
Documentation
79(1)
Project Plan
80(1)
Scope Management
80(1)
Conclusion
81(1)
Technical Design Review: Analyze Phase
82(1)
Technical Design Review
82(3)
Gate 2 Readiness: Analyze Phase
83(1)
Assessment of Risks
83(2)
9 Gathering the Voice of the Customer
85(8)
VOC in Product Development
85(1)
Customers/Stakeholders
86(1)
Voice of the Customer
87(1)
Critical to Satisfaction
88(1)
Critical to Quality
89(1)
Conclusion
90(3)
10 Quality Function Deployment
93(12)
Kano Model
93(1)
Quality Function Deployment
94(10)
Conclusion
104(1)
11 Triz
105(10)
Triz Methodology
105(1)
Nine Windows
106(1)
Triz Methodology
107(6)
Contradictions
108(1)
Technical Contradictions
108(1)
Physical Contradictions
108(1)
Separation Principle
108(1)
Contradiction Matrix
109(1)
The 40 Principles of Invention
109(1)
Triz and DFSS
109(4)
Conclusion
113(2)
12 Lean Design
115(12)
Single-Minute Exchange of Dies (SMED)
118(8)
What Is SMED?
118(8)
Conclusion
126(1)
13 Design for X Methods
127(4)
Design for Manufacturability
127(1)
Design for Assembleability
127(1)
Design for Reliability
128(1)
Design for Serviceability
128(1)
Design for Environment
129(1)
Design for Testability
129(1)
Conclusion
129(2)
14 Pugh Concept Selection Matrix
131(8)
Conclusion
136(3)
15 Modeling of Technology
139(8)
Ideal Function
139(2)
P-Diagram
141(2)
Functional Analysis System Technique
143(1)
Conclusion
144(3)
16 Taguchi Design
147(26)
Taguchi Loss Function
147(2)
Mahalanobis--Taguchi System
149(3)
Multidimensional Systems
152(1)
Mahalanobis--Taguchi Steps
153(4)
Step 1 Normal Group Calculations
153(2)
Step 2 Normal Space Calculations
155(1)
Step 3 Test (Abnormal) Group Calculations
155(1)
Step 4 Optimize the System
156(1)
MTS Steps Using the Graduate Admission System Example
157(14)
Step 1 Normal Group Calculations
158(4)
Step 2 Normal Space Calculations
162(1)
Step 3 Test Group Calculations
163(3)
Step 4 Optimize the System
166(5)
Conclusion
171(2)
17 Design Failure Modes and Effects Analysis
173(12)
Failure Modes and Effects Analysis
173(6)
Poka Yokes
179(4)
Conclusion
183(2)
18 Design of Experiments
185(8)
Design of Experiments (DOE)
185(6)
Conclusion
191(2)
19 Reliability Testing
193(8)
Types of Systems
196(2)
Redundant Systems
198(3)
20 Measurement Systems Analysis
201(12)
Gauge R&R
203(6)
Conclusions
209(1)
Technical Design Review: Design Phase
209(4)
Technical Design Review
210(1)
Gate 3 Readiness: Design Phase
211(1)
Assessment of Risks
211(2)
21 Capability Analysis
213(8)
Capability Analysis
213(1)
Control Charts
214(3)
X-Bar and Range Charts
215(1)
Calculation of Control Limits
216(1)
Plotting Control Charts for R- and X-Bar Charts
217(1)
Plotting Control Charts for MR and Individual Control Charts
217(1)
Defects per Million Opportunities (DPMO)
217(2)
Conclusion
219(2)
22 Statistical Process Control
221(12)
Control Charts
223(8)
X-Bar and Range Charts
224(1)
Calculation of Control Limits
224(1)
Plotting Control Charts for Range and Average Charts
225(1)
Plotting Control Charts for Moving Range and Individual Control Charts
225(1)
X-Bar and Range Charts
226(2)
Attribute Data Formulas
228(3)
Conclusions
231(2)
23 Future and Challenges of Design for Six Sigma
233(6)
Engagement and Success Factors
234(1)
Technical Design Review: Verify Phase
235(4)
Technical Design Review
236(1)
Gate 4 Readiness: Verify/Validate Phase
237(1)
Assessment of Risks
237(2)
24 Design for Six Sigma Case Study: Sure Mix Gas Can
239(20)
Project Description
239(3)
Project Goals
239(1)
Project Expectations
240(1)
Project Boundaries (Scope)
240(1)
Project Management
240(2)
Invent/Innovate
242(3)
Benchmarking
242(1)
Voice of the Customer
242(1)
Affinity Diagram
243(1)
House of Quality
243(2)
Kano Analysis
245(1)
Design for X Methods
245(2)
Concept Generation
247(6)
Technology Modeling
253(1)
Robustness/Tunability
253(1)
System Additive Model
254(1)
Variational Sensitivities and System Variance Model
255(1)
Customer Reviews
255(1)
Lessons Learned
256(1)
Future Project Targets
256(1)
Field Testing (Prototype Acceptance)
257(1)
Summary
257(1)
Conclusion
258(1)
25 Design for Six Sigma Case Study: Portable Energy Solutions
259(22)
Project Description
259(1)
Project Goals
260(1)
Requirements and Expectations
260(1)
Project Boundaries
260(1)
Project Management
261(1)
Invent/Innovate
261(2)
Quality Function Deployment (QFD)
263(2)
Kano Analysis
265(2)
Develop
267(5)
Design for X Methods
267(1)
Concept Generation
267(5)
Modeling of Technology
272(2)
Super Concept
273(1)
Pugh's Concept Selection
274(1)
Optimize
274(1)
Modeling of Robustness
274(1)
Verify
274(4)
Design Failure Mode and Effects Analysis
274(4)
System Variance Model
278(2)
Develop and Confirm Robustness Additive Models
278(2)
Conclusion
280(1)
26 Design for Six Sigma Case Study: Paper Shredder
281(20)
Project Description
281(1)
Project Goals and Requirements
282(1)
Project Management
282(1)
Invent/Innovate
282(4)
Gathering the Voice of the Customer (VOC)
282(1)
Voice of the Customer
283(1)
Quality Function Deployment (QFD)
284(2)
Develop
286(9)
Design for X Methods
286(1)
Concept Generation
286(4)
Pugh Concept Selection Matrix
290(2)
Final Design
292(1)
Design Failure Modes and Effects Analysis (DFMEA)
293(2)
Optimization
295(2)
Robustness and Tunability
295(1)
System Additive Model
296(1)
Verify
297(2)
Customer Feedback
297(1)
Robustness Evaluation
297(2)
Conclusion
299(2)
27 Design for Six Sigma Case Study: Universal iPhone Dock
301(20)
Project Description
301(2)
Project Goals
302(1)
Requirements and Expectations
302(1)
Project Boundaries
303(1)
Project Management
303(5)
Voice of the Customer
303(1)
Customer Survey
303(2)
Survey Results
305(2)
Affinity Diagram
307(1)
Quality Function Deployment (QFD)
307(1)
Kano Analysis
308(2)
One-Dimensional Quality
310(1)
Expected Quality
310(1)
Exciting Quality
311(1)
Concept Generation
311(2)
Pugh Concept Selection Matrix
311(2)
Final Design
313(2)
Design Failure Modes and Effects Analysis (DFMEA)
315(1)
Final Design Prototype
316(3)
Verification
318(1)
Testing
318(1)
Conclusion
319(2)
28 Design for Six Sigma Case Study: Hospital Bed
321(20)
Designing a Hospital Bed for Improving Stakeholders' Level of Care
321(1)
Design for Six Sigma Overview
321(3)
Project Description
321(1)
Project Goals
322(1)
Requirements and Expectations
322(1)
Project Boundaries
322(1)
Project Management
323(1)
Invent/Innovate Phase
324(3)
Voice of the Customer
324(1)
KJ Analysis and Kano Model
324(3)
Quality Function Deployment
327(1)
Develop Phase
328(7)
Design for X Methods and Concept Generation
328(7)
Pugh Concept Selection Matrix
335(4)
Verify
336(1)
Optimize
336(2)
Tips to Improve Our Design
338(1)
Final Design Prototype: Concept 7
338(1)
Conclusion
339(2)
Glossary 341(8)
Index 349
Elizabeth Cudney, Ph.D. is an Associate Professor in the Engineering Management and Systems Engineering Department at Missouri University of Science and Technology. She received her B.S. in Industrial Engineering from North Carolina State University, Master of Engineering in Mechanical Engineering and Master of Business Administration from the University of Hartford, and her doctorate in Engineering Management from the University of Missouri Rolla.





In 2014, Dr. Cudney was elected as an ASEM Fellow. In 2013, Dr. Cudney was elected as an ASQ Fellow. In 2010, Dr. Cudney was inducted into the International Academy for Quality. She received the 2008 ASQ A.V. Feigenbaum Medal and the 2006 SME Outstanding Young Manufacturing Engineering Award. She has published four books and over 40 journal papers. She is an ASQ Certified Quality Engineer, Manager of Quality/Operational Excellence, and Certified Six Sigma Black Belt. She is a member of the ASEE, ASEM, ASQ, IIE, and the Japan Quality Engineering Society (JQES).





Tina Agustiady is a certified Six Sigma Master Black Belt and Continuous Improvement Leader at BASF. Tina serves as a strategic change agent, infusing the use of Lean Six Sigma throughout the organization as a key member of the Site Leadership team. Tina improves cost, quality, and delivery at BASF through her use of Lean and Six Sigma tools while demonstrating the improvements through a simplification process. Tina has led many Kaizen, 5s, and Root Cause Analysis events through her career in the healthcare, food, and chemical industries.

Agustiady received a BS in industrial and manufacturing systems engineering from Ohio University. She earned her Black Belt and Master Black Belt certifications at Clemson University. Agustiady is also the Institute of Industrial Engineers (IIE) Lean Division board director and chairman for the IIE annual conferences and Lean Six Sigma conferences. She is an editor for the International Journal of Six Sigma and Competitive Advantage.