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viii Contents

3.12 Features of a Sound DFSS Strategy 101
Appendix: Historical Development in Design 103
Chapter 4. Design for Six Sigma Deployment 107
4.1 Introduction 107
4.2 Black Belt–DFSS Team: Cultural Change 107
4.3 DFSS Deployment Prerequisites 110
4.4 DFSS Deployment Strategy 112
4.5 DFSS Deployment Strategy Goals 115
4.6 Six Sigma Project Financial Management 122
4.7 DFSS Training 123
4.8 Elements Critical to Sustain DFSS Deployment 123
4.9 DFSS Sustainability Factors 124

Chapter 5. Design for Six Sigma Project Algorithm 129
5.1 Introduction 129
5.2 Form a Synergistic Design Team (DFSS Algorithm Step 1) 132
5.3 Determine Customer Expectations (DFSS Algorithm Step 2) 133
5.4 Understand Functional Requirements Evolution
(DFSS Algorithm Step 3) 147
5.5 Generate Concepts (DFSS Algorithm Step 4) 148
5.6 Select the Best Concept (DFSS Algorithm Step 5) 152
5.7 Finalize the Physical Structure of the Selected
Concept (DFSS Algorithm Step 6) 153
5.8 Initiate Design Scorecards and Transfer Function
Development (DFSS Algorithm Step 7) 157
5.9 Assess Risk Using DFMEA/PFMEA (DFSS Algorithm Step 8) 159
5.10 Transfer Function Optimization (DFSS Algorithm Step 9) 167
5.11 Design for X (DFSS Algorithm Step 10) 175
5.12 Tolerance Design and Tolerancing (DFSS Algorithm Step 11) 176
5.13 Pilot and Prototyping Design (DFSS Algorithm Step 12) 178
5.14 Validate Deign (DFSS Algorithm Step 13) 179
5.15 Launch Mass Production (DFSS Algorithm Step 14) 180
5.16 Project Risk Management 181
5.17 Other DFSS Roadmaps 183

Chapter 6. DFSS Transfer Function and Scorecards 185
6.1 Introduction 185
6.2 Design Analysis 186
6.3 DFSS Design Synthesis 186
6.4 Design Scorecards and Transfer Function Development 195
Chapter 7. Quality Function Deployment (QFD) 213
7.1 Introduction 213
7.2 History of QFD 215
7.3 QFD Benefits, Assumptions, and Realities 215
7.4 QFD Methodology Overview 216
7.5 Kano Model of Quality 224