Page 120 - Design for Six Sigma a Roadmap for Product Development

Product Development Process and Design for Six Sigma 95

■ Taguchi method, parameter design, tolerance design
■ Reliability-based design
■ Robustness assessment

3.7.4 Phase 4: Validate the design (V)
After the parameter and tolerance design is completed, we will move
to the final verification and validation activities.
Step 1: Pilot test and refining. No product or service should go directly
to market without first piloting and refining. Here we can use design
failure mode–effect analysis (DFMEA) as well as pilot and small-scale
implementations to test and evaluate real-life performance.

Step 2: Validation and process control. In this step we will validate the
new entity to make sure that the end result (product or service) as
designed meets the design requirements and that the process controls
in manufacturing and production are established in order to ensure
that critical characteristics are always produced to specification of the
optimization (O) phase.

Step 3: Full commercial rollout and handover to new process owner. As
the design entity is validated and process control is established, we
will launch full-scale commercial rollout and the new entity, together
with the supporting processes, can be handed over to design and
process owners, complete with requirements settings and control and
monitoring systems.
The following DFSS tools are used in this phase:

■ Process capability modeling
■ DOE
■ Reliability testing
■ Poka-yoke, errorproofing
■ Confidence analysis
■ Process control plan
■ Training

3.8 More on Design Process
and Design Vulnerabilities

An efficient DFSS application can be achieved when analytical tools
are combined with science-based design tools such as axiomatic design
(Suh 1990), where modeling of the “design structure” carries great