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Full Description
This book is a complete look at the steps necessary to successfully bring innovative new prdocuts to market. Using the tools of DFSS, the book presents step by step instructions for business case development, financial benefit assessment, product concept development, product design, and final manufacturing scale-up. It will help the business manager and design team identify the product concepts important to customers and efficiently translate these products into high impact sources of new revenue. Along with a step by step discussion of key DFSS tools and roadmaps, the book contains a detailed case study example to illustrate what is being explained. The author draws upon his experience consulting on Six Sigma implementations at major companies, including BASF, WR Grace, TRW, and Johnson Wax. By applying the methods presented in this book, a company can quickly and significantly improve its product development process.
Contents
Preface ix Acknowledgments xvii About the Authors xix Section I Getting Started 1 Chapter 1 What Is Design for Six Sigma? 3 Design for Six Sigma Defined 3The Risk of Development 4A Little History 5An Overview of the Methodology 7Chapter 2 The Business Case for DFSS 11 The Product Life Cycle 11Where Have All the Vacuum Tubes Gone? 13Understanding Dynamic Markets: The Kano Model 15The Role of DFSS 18Chapter 3 Six Sigma Financial Metrics 21 Candy Wrapper Film: A DFSS Case Study 21How to Measure Success in a DFSS Project 22The Cost of Long-Term Variation 33Chapter 4 Project Identification and Portfolio Management 41 Linking Projects to Strategy 41The Project Charter 42DFSS Projects Linked to Financial Results 43Project Hopper and Pipeline Management 46Managing the Commercialization Pipeline 48Technology Platform Projects 48Project Pipeline Scorecard 48Chapter 5 Stage-Gate Processes 51 The Stage-Gate Structure 51Stage-Gate 1: Opportunity Assessment 53Stage-Gate 2: Market Analysis and Product Definition 55Stage-Gate 3: New Product Concept Finalized 55Stage-Gate 4: Design of the New Product and Supporting Manufacturing Process 58Stage-Gate 5: Validate Product and Process Design 58Stage-Gate 6: Product Launch Plan 60Managing the Stage-Gate Process 62Chapter 6 Project Management 67 DFSS Project Roadmaps 67Developing the Project Schedule 69Project Schedule Management 73Good Project Management 74Section II Preparing the Business Plan 75 Chapter 7 Business Plan Overview 77 Review of the Business Plan at Gate 3 77Components of the Business Plan 77Chapter 8 Market Segmentation 83 The Financial Value of Market Segmentation 83Developing the Segmentation Strategy 89Chapter 9 Identifying Market Opportunities 93 The SWOT Analysis 93Developing the Ratings by Market Segment 95SWOT Analysis Results 97The Market FMEA 98Chapter 10 Defining Product Value 101 The Value Concept 101Making Quality a Weapon 102Mapping the Value Chain 105Tools for Defining Value 107Chapter 11 Estimating Financial Value 109 Calculating the Project Value 109How to Handle Fixed Costs 110Examining the Project Returns 115Chapter 12 Product Positioning 123 The Market Perceived Quality Profile 123Product Positioning Maps 129Section III The Voice of the Customer 131 Chapter 13 Concept Development 133 The Concept Development Process 133Concept Development Applications 135Advantages of the Concept Development Process 135Chapter 14 Developing the Interview Guide 139 Developing a Purpose Statement 139Identifying and Listing Five to Ten Bullet-Point Interview Objectives 140Developing a Customer Selection Matrix 141Creating the Interview Guide Questions 143Chapter 15 Conducting Customer Interviews 151 Preparing for the Interviews 151Interview Team Roles 152Conducting the Interview 153Debriefing the Interview 155Good Project Management of the Interview Process 155Practice, Practice, Practice 156Chapter 16 KJ Analysis 157 An Overview of the KJ Process 158The Image KJ 158The Requirements KJ 168The Next Steps 178 Chapter 17 Relative Importance Survey 179 Designing and Conducting the Survey 179Analyzing the Survey Results 183Identifying Requirements in Kano Terms 185Chapter 18 Ideation 187 The Ideation Process 187Ideation in the Candy Wrapper Film Case Study 190Chapter 19 Pugh Concept Selection 193 The Pugh Concept Selection Process 194Pugh Concept Selection in the Candy Wrapper Film Case Study 198Chapter 20 QFD 199 The Value of QFD 199Executing the QFD 201The QFD Flowdown 206QFD across the Value Chain 209Some Final Thoughts 215Chapter 21 TRIZ 217 Technical Contradictions 218The TRIZ Methodology 218Some Final Thoughts on TRIZ 229Chapter 22 Critical Parameter Management 231 Documenting Critical Information from the QFD 232The Critical Parameter Scorecard 232The Benefits of Using Critical Parameter Scorecards 236Section IV Product/Process Development 239 Chapter 23 Process Mapping 241 Types and Uses of Process Maps 241The Process Variables Map 241The "As-Is/Can-Be" Process Map 247Some Final Thoughts on Process Mapping 249Chapter 24 Cause and Effects Matrix 251 Comparing C&E Matrix and QFD3 251Developing the C&E Matrix 252Using the C&E Matrix Output 257Chapter 25 Failure Modes and Effects Analysis 263 Two Types of FMEA in New Product Development 263The Design FMEA 264The Process Design FMEA and the Process Manufacturing FMEA 271Chapter 26 Statistical Analysis Tools Overview 275 Variation in Product and Process Development 275Some Basic Statistics 279Graphical Analysis Techniques 282Numerical Descriptive Statistics 301A Look Ahead 303Chapter 27 Measurement Systems Analysis 307 Measurement System Error 307The Impact of Measurement Error in Development 308Assessing Measurement System Usefulness 309Conducting a Measurement System Study 316Long-Term Measurement System Assessments 322Chapter 28 Process Capability 323 Using the Normal Distribution Curve to Estimate Waste 323Short-Term Process Capability Analysis 325Long-Term Process Variation: The Shift 326Designing for Six Sigma Performance 329Revisiting the Cp Statistic 330The Cpk Statistic 332Long-Term Process Capability Analysis 335Interpreting the Capability Indices 336Capability Analysis in Minitab 337Ensuring Measurement System Adequacy 341Process Capability for Attribute Data 343The Importance of Process Capability 344Chapter 29 Tools for Data Analysis 347 General Methods of Data Analysis 347Hypothesis Testing 348Sample Size Calculation 350Comparing a Process Mean to a Target Value 352Comparing Means and Standard Deviations from Two Film Samples 359Comparing Two Variances 364Comparing Two Means: 2-Sample t-test 364Comparing 2 Medians: The Mann-Whitney Test 367Comparing Two Means: Paired Comparisons 367Assessing Means and Standard Deviations: Con*dence Interval 371Comparing Means and Standard Deviations from More Than Two Samples 374Comparing Variance 377Comparing Means: One-Way ANOVA 379Comparing Medians: Kruskal-Wallis Test 384Data Comparison Tools Summary 385Correlation Analysis 385Regression Analysis for a Single Input Variable 388Multiple Regression Analysis 394Correlation and Regression Analysis Summary 400References 400Chapter 30 Design of Experiments 401 Full Factorial Designs 401Fractional Factorial Designs 415Response Surface Designs 424Choosing an Experimental Design 430References 432Chapter 31 Robust Design 433 Quantifying Robust Design Performance 433The Taguchi Approach to Robust Design 435Robust Design Example 438Alternative Approaches to Robust Design 442Dealing with Variation 447Chapter 32 Mixture Experiments 449 Mixture Equations 449Mixture Designs 451Creating Mixture Designs in Minitab 451Analyzing a Mixture Design Experiment 455Response Surface Study for a Mixture Investigation 458Choosing a Mixture Design 466References 468Chapter 33 Seeking an Optimal Solution 469 The Multiple Response Optimization Process 470Three-Response Optimization 477Monte Carlo Simulation in Optimization 481Multiple Response Optimization Final Thoughts 488Chapter 34 Design for Reliability 491 A Roadmap for Reliability 491Design for Reliability 493Identifying Reliability Requirements: VOC 493Reliability Expectations and the Kano Model 494Customer Reliability Expectations 495Typical Reliability Metrics 495The Hazard Function 498Types of Reliability Tests 503Reliability and Failure Modes and Effects Analysis 506Reliability Functions and Mathematical Models 508Types of Distributions and the Hazard Function 511Reliability Modeling Using Minitab Software 512The Implications of Product Reliability on Warranty Costs 516Chapter 35 Statistical Tolerancing 519 Worst Case Analysis 520Root Sum of Squares Analysis 521Six Sigma Tolerance Analysis 525Chapter 36 Production Scale-up 541 Confirming the Product 542Design for Manufacturability Assessment 550Scaling up the Product 553Chapter 37 Control Plans 559 Developing a Control Plan 560The Final Control Plan Package 572Section V Product Launch and Project Post-Mortem Analysis 575 Chapter 38 Product Launch and Project Post-Mortem Analysis 577 Product Launch Planning 577Project Post-Mortem Analysis 583Conclusions 588Appendix A Glossary 589 Appendix B Abbreviations 599 Index 601
