Page 205 - Design for Six Sigma a Roadmap for Product Development

178 Chapter Five

5.13 Pilot and Prototyping Design
(DFSS Algorithm Step 12)
The objective of this step is to verify that the Six Sigma optimized
design performs at a level that is consistent with the specifications. To
accomplish this, a single, productionlike prototype is created in this
step, which provides a framework for the systematic identification and
efficient resolution of problems. In the product design scenario, this
step also includes the verification of certain service-related and
production/manufacturing-related support activities, such as mainte-
nance procedures, packaging, dunnage, and shipping systems.
The DFSS team should identify processes, parts, and assemblies for
prototype testing as they note which are carryovers and which are the
results of new designs or Six Sigma optimization. The team proceeds
to define test hierarchy (e.g., component, subsystem, and system) use
specification, and FMEA information to identify tests normally per-
formed to verify FR performance. The following are the major steps in
this prototyping step:

1. Begin developing a total test matrix.
2. Define testing acceptance criteria.
3. Evaluate measurement systems (e.g., gauge R&R).
4. Develop a detailed testing schedule.
5. Establish a production resemblance plan.
6. Assemble a total prototype test plan.
7. Get test plan approval.
8. Order parts and build prototypes; procure prototype and produc-
tion parts and assemblies, as necessary in the physical structure,
to support testing based on step 4 (above).
9. Conduct the test.
10. Evaluate and analyze the results.
11. Verify service procedures and industrial engineering time studies.
This activity verifies that the design work performed during the
previous steps provides effective service for all systems and key
subsystems and components. Design and process review of the
project and supporting processes documentation will verify the
design.

With these steps, it may be useful to calculate the prototype capability
and compare this with internal capability of similar and baseline
designs. Design prototypes in the category of incremental design made
on the same production lines will assume the baseline process capability.