Page 206 - Design for Six Sigma a Roadmap for Product Development

Design for Six Sigma Project Algorithm 179

The prototype sample of high-volume creative design and those out-
sourced to suppliers will use the applicable high-volume prototype
sample testing (e.g., normality and pooled variance hypothesis testing
are generally used). Low-volume creative design prototype samples
can be estimated using 2 (chi-square) distribution.

5.14 Validate Deign (DFSS Algorithm Step 13)

This step provides a rapid, smooth confirmation of the design struc-
tures including manufacturing, assembly, and production capability,
with the need for minimal refinements. Design and process specifica-
tions are completed and released before the start of this confirmation
step of the DFSS algorithm. This step covers the installation of the
equipment and the manufacture and evaluation of a significant pro-
duction sample, which is produced under conditions of mass produc-
tion. Production validation testing is used to verify that the process is
producing a design that meets the FRs derived from the customer
attributes. A functional evaluation of the design by the customer and
DFSS team provides additional verification that design intent has
been achieved.
Prior to installation, production processes should have already been
optimized in the presence of potential sources of production and cus-
tomer usage “noise” and have demonstrated potential capability both
in house and at the supplier location. These activities have involved
significant simulated production runs and form the basis for a low-risk
installation at the intended facilities.
The DFSS team should identify the unanticipated installation trial
concerns to ensure that the corrective actions are implemented prior
to launch. Manufacturing and/or production capability is assessed and
the process is exercised in a manner that would be expected for normal
production operation.
The team needs to visit the training programs with focus on the
transfer of knowledge from DFSS team to the on-site production per-
sonnel, including standby labor. This transfer of knowledge enables the
operation individuals to add and improve on the control plan as they
add their individual skills to the production planning.
The DFSS team membership should be enhanced to include more
skills and expertise necessary to confirm production capability and to
initiate an effective launch. Much of the earlier planning work done for
quality control and maintainability of the process will be executed dur-
ing the launch phase of production. The new team members who will
participate in the launch now have to prepare themselves by review-
ing the process documentation and control plans. This documentation,
combined with supporting discussion by the new team members, will