Page 50 - Six Sigma for electronics design and manufacturing

Six Sigma for Electronics Design and Manufacturing
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The objectives of DFM are more focused on design for low cost. This
is accomplished through fewer parts, parts that are standardized, or
parts that are easier for operators or production machines to assem-
ble, hence requiring lower operator skills. The result of DFM analysis
could be very beneficial toward achieving the goal of six sigma. A well-
designed DFM part or assembly can have a much wider tolerance, or
it can be easier to manufacture, resulting in reduced assembly de-
fects. In addition, the design team can focus better on a smaller num-
ber of parts.
An interesting consequence of applying DFM to new designs, which
will be discussed in the next chapter, results from the reduction in the
number of parts. Each additional part carries with it a potential for
more defects. A smaller number of parts reduces the opportunities to
generate defects, hence making the part design more robust and clos-
er to the six sigma goal.
1.10 Design of Experiments (DoE)
Though this quality tool will be discussed in detail in Chapter 7, a
quick review is given in this chapter in order to round out the quality
tools integration with the six sigma principles. Much like QFD, design
of experiments (DoE) can be used in both design and manufacturing,
and hence can influence both parts of the six sigma equation: design
specifications and manufacturing variability.
DoE can be used in order to focus the new product development
project not only on cost, as in DFM, but on several other areas such
as quality, variability reduction, and specification selection. The
same set of experiments can be used to optimize any of the parame-
ters mentioned above: product cost, quality, or specifications. DoE
has been widely used in manufacturing, but not in design, much like
six sigma. It is the intent of the author to demonstrate the success-
ful use of DoE in design as well as manufacturing, especially in case
studies where it was used to enhance the attainment of the six sig-
ma goals.

1.11 Other Quality Tools
There is a wide range of tools necessary for the planning, mainte-
nance, and troubleshooting of quality problems and defects. These
tools include quality planning tools that are helpful in estimating and
planning for contingencies when a new product is launched, or when a
production process is being upgraded or improved. They include the
tools described in the following subsections.