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1. Design for Six SigmaDesign for Six Sigma
Design for Six SigmaDesign for Six Sigma
Prepared By :Prepared By :
SHAIVYA GUPTASHAIVYA GUPTA
B.Tech. EN VI semB.Tech. EN VI sem

2. Design for Six SigmaDesign for Six Sigma
What is a SIGMA ?What is a SIGMA ?
• A metric that indicates how well a process is performing.
• Higher is better.
• Measures the capability of the process to perform defect-free work.
• Also known as “z”, it is based on standard deviation for continuous data.
• For discrete data it is calculated from DPMO [Defects Per (one) Million Opportunities].
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3. Design for Six SigmaDesign for Six Sigma
Six SigmaSix Sigma ::
Unacceptable deviation from the mean or target
Accuracy & precision of a process can be best explained by
using the analogy of a rifle firing at a target.
Six Sigma is a methodology to manage process
variations that cause defects,t; and to
systematically work towards managing variation to
eliminate those defects. The objective of Six
Sigma is to deliver high performance, reliability,
and value to the end customer. It was pioneered
by Bill Smith at Motorola in 1986 and was
originally defined as a metric for measuring
defects and improving quality; and a methodology
to reduce defect levels below 3.4 Defects Per
(one) Million Opportunities.
(DPMO), or another way, a methodology of controlling a process to the point
of ± six sigma (standard deviations) from a centerline.

4. Design for Six SigmaDesign for Six Sigma
Six SigmaSix Sigma :: methodology
Six Sigma follows the methodology DMAIC
Basic methodology consists of the following five phases:
Define:Define: formally define the process improvement goals that are consistent with
customer demands and enterprise strategy.
Measure:Measure: to define measurements on current process for future comparison. Map
and measure the process in question and collect required process data.
Analyze:Analyze: to verify relationship and causality of factors. What is the relationship? Are
there other factors that have not been considered?
Improve:Improve: optimize the process based upon the analysis using techniques like Design
of Experiments.
Control:Control: setup pilot runs to establish process capability, transition to production and
thereafter continuously measure the process and institute control mechanisms to
ensure that variances are corrected before they result in defects.

5. Design for Six SigmaDesign for Six Sigma
MaterialMaterial
AssembliesAssemblies
ComponentsComponents
SuppliersSuppliers
ConsumablesConsumables
MeasurementMeasurement
CountingCounting
InstrumentsInstruments
GaugingGauging
TestsTests
EnvironmentEnvironment
Noise levelNoise level
HumidityHumidity
TemperatureTemperature
LightingLighting
MachineMachine
TechnologyTechnology
VariabilityVariability
ToolingTooling
FixturesFixtures
MethodsMethods
ProceduresProcedures
PoliciesPolicies
AccountingAccounting
PeoplePeople
TrainingTraining
ExperienceExperience
SkillSkill
VariationVariation
Sources of Variations and Defects :Sources of Variations and Defects :

6. Design for Six SigmaDesign for Six Sigma
DFSS (Design for Six Sigma) :DFSS (Design for Six Sigma) :
PreSolution to future Problems
DFSS has a different objective ,that of determining
the needs of customers and the business, and
driving those needs into the product solution
created.

7. Design for Six SigmaDesign for Six Sigma
Business ChallengesBusiness Challenges
Customers demand product excellence
• Excellence is defined as the ideal balance of product attributes, such as Cost, Quality,
Performance, Aesthetics, Packaging, etc.
• Manage variability of customer-facing product attributes.
• Improve the predictability and capability of the product development process.
Market demands reduced costs and increased profitability
•Increase product development process effectiveness.
•Directly meet customer requirements.
•More effectively manage product development costs.

8. Design for Six SigmaDesign for Six Sigma
Design for Six Sigma follows method DMADV.
Basic methodology consists of the following five phases:
Define:Define: formally define the goals of the design activity that are consistent with
customer demands and enterprise strategy.
Measure:Measure: identify CTQs (critical to qualities), product capabilities, production
process capability, risk assessment, etc.
Analyze:Analyze: develop and design alternatives, create high-level design and evaluate
design capability to select the best design.
Design:Design: develop detail design, optimize design, and plan for design verification.
This phase may require simulations.
Verify:Verify: design; setup pilot runs, implement production process and handover to
process owners.
DFSS (Design for Six Sigma) :DFSS (Design for Six Sigma) : Methodology

9. Design for Six SigmaDesign for Six Sigma
Differences between Six Sigma and DesignDifferences between Six Sigma and Design
For Six SigmaFor Six Sigma
Six SigmaSix Sigma Design for Six SigmaDesign for Six Sigma
• DMAIC : Define, Measure, Analyze,
Improve, Control
• DMADV: Define, Measure, Analyze,
Design Improve, Control and Verify
• DMADOV: Define, Measure, Analyze,
Design, Optimize, and Verify
Looks at existing processes and fixes
Problems.
Focuses on the up-front design of the
product and process
More reactive More Proactive
Dollar benefits obtained from Six Sigma
can be quantified rather quickly.
Benefits are more difficult to quantify and
tend to be more long-term. It can take six to
12 months after the launch of the new
product before you will obtain proper
accounting on the impact.

10. Design for Six SigmaDesign for Six Sigma
StartStart
Does Product/serviceDoes Product/service
Currently Exists?Currently Exists?
OptimizeOptimize
ValidateValidate
DefineDefine
MeasureMeasure
AnalyzeAnalyze
ImproveImprove
Is improvementIs improvement
sufficientsufficient
????/????/
IdentifyIdentify
DesignDesign
ControlControl
Yes
No
YesNo
DFSSDFSS TraditionalTraditional
Six SigmaSix Sigma
The Big Picture :The Big Picture :
EndEnd

11. Design for Six SigmaDesign for Six Sigma
““You don’t know what you don’t know.”You don’t know what you don’t know.”
-Mikel Harry, co-founder of the Six Sigma Academy
Predicting Design BehaviorPredicting Design Behavior
DFSS now looks to predict how the designs under
consideration will behave. Numerous engineering and
statistical methods provide the basis for prediction.
DFSS provides a structured way to constructively use
the information learned from such unknown events in
the next program.

12. Design for Six SigmaDesign for Six Sigma
Examples:Examples: Simulation and High Performance Computing (HPC)
Simulation of stress and vibrations of turbinSimulation of stress and vibrations of turbin
assembly for use in nuclear power generationassembly for use in nuclear power generation
powerpower
AutomotiveAutomotive
Simulation of underhood thermal cooling for decreaseSimulation of underhood thermal cooling for decrease
in engine space and increase in cabin space and comfortin engine space and increase in cabin space and comfort
AerospaceAerospace
ElectronicsElectronics
Evaluation of dual bird-strike on aircraft engineEvaluation of dual bird-strike on aircraft engine
nacelle for turbine blade containment studiesnacelle for turbine blade containment studies
Evaluation of cooling air flow behaviorEvaluation of cooling air flow behavior
inside a computer system chassisinside a computer system chassis

13. Design for Six SigmaDesign for Six Sigma
Examples:Examples: Computer Aided Engineering (CAE) and Simulation
Software
Mechanical motion:Mechanical motion:
Multibody kinetics and dynamicsMultibody kinetics and dynamics
Implicit Finite Element Analysis:Implicit Finite Element Analysis: Linear and nonlinearLinear and nonlinear
statics, dynamic responsestatics, dynamic response
Explicit Finite Element Analysis :Explicit Finite Element Analysis : Impact simulation,Impact simulation,
metal formingmetal forming
General Computational Fluid Dynamics:General Computational Fluid Dynamics: Internal andInternal and
external flow simulationexternal flow simulation

14. Design for Six SigmaDesign for Six Sigma
Application and success:Application and success:
Healthcare
"A Six Sigma process improvement team charged with getting heart attack patients from the Emergency
Department into the cardiac catheterization lab for treatment faster slashed 41 minutes off the hospital's mean
time"
Banking
Bank of America has used Six Sigma for credit risk assessment reduction, fraud prevention, and customer satisfaction
improvement, etc.
Insurance
Insurance companies have used Six Sigma for critical tasks like premium outstanding reduction and various cycle time
reductions. For example, CIGNA Dental reports pending claim volume reduction by over 50%.
Construction
In engineering and construction of the Channel Tunnel Rail Link project in the UK, the Bechtel’s project team uncovered a way to
save hundreds of job hours on one of the tunneling jobs.
The Institute of Quality Assurance has interesting success stories on Wipro, Citibank, and Motorola.
Military
The United St ates Navy has adopted Six Sigma as part of AIRSpeed, an overall set of practices designed to improve efficiency
in aviation maintenance.
Programming
JPMorgan Chase & Co. tried combining Six Sigma with the computer programming methodologies of Extreme Programming
(XP), and Capability Maturity Model Integration (CMMI).

15. Design for Six SigmaDesign for Six Sigma
Problems in implementing Six Sigma at these places
1. Millions of dollars in investment is required
2. Dedication of their best full time resources
3. Training of the masses

16. Design for Six SigmaDesign for Six Sigma
That’s all for Now !!!That’s all for Now !!!