Page 157 - Design for Six Sigma a Roadmap for Product Development

Design for Six Sigma Project Algorithm 131

The DFSS algorithm has four phases: I (identify), C (characterize),
O (optimize), and V (validate), denoted ICOV as depicted in Fig. 5.1.
The objective of this chapter is to mold DFSS principles, tools, and
phases in a comprehensive implementable sequence in a manner
that consolidates the advantages of both algorithmic and principle-
based approaches, and link the algorithm to the design entity total
life cycle. The life cycle of a design entity, whether a product, a ser-
vice, or a process, is usually formed and modeled using phases and
tollgates. A “phase” represents a set of design activities of the project
and is usually bounded by an entrance tollgate and an exit tollgate.
A “tollgate” represents a milestone in the life cycle and has some for-
mal meaning defined by the development process, cascaded to the
design team, and recognized by management and other stakeholders.
The life cycle of a designed entity, whether a product, a service, or a
process, starts with some form of idea generation, whether in free
invention format or using more disciplined creativity such as those
surfaced by R&D departments. This is usually followed by several
sequential activities. In the life cycle, the design process is followed
by manufacturing or production activities followed by service, and
aftermarket support. The design stages (phases) are described in
Chap. 1.
In this algorithm, we emphasize the DFSS cross-functional team. A
well-developed team has the potential to design winning Six
Sigma–level solutions. Winning is contagious as successful design
teams foster other DFSS teams. The growing synergy, which arises
from ever-increasing numbers of successful teams, accelerates
deployment throughout the company. The payback for small, upfront
investments in team performance can be enormous. Continuous vigi-
lance on the part of the black belt at improving and measuring team
performance throughout the project life cycle will be rewarded with
ever-increasing capability and commitment to deliver winning design
solutions.
As depicted in Fig. 5.1, the process proposed here requires informa-
tion and data to correctly formulate the objective of the design project.
Correct formulation of the objective of the design project ranges from
changes or modifications (incremental design) to very new design
(creative design). In the algorithm presented here, the project option
must be assessed on or before the conclusion of step 2 in a manner sug-
gested by Fig. 5.2. Figure 5.3 is the step roadmap. If the results of the
current step do not meet its objective, they might, nevertheless, prove
useful if the objectives were wholly or partially changed. Accordingly,
the degree of intensity in executing the different algorithm steps will
vary. Occasional reference to either scenario will be highlighted when
necessary.