DFSS, Innovation and I-TRIZ Tools
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Transcript of DFSS, Innovation and I-TRIZ Tools
DFSS, Innovation and I-TRIZ Tools
“Innovative Designs for Six Sigma”
DFSS, Innovation and I-TRIZ Tools
“Innovative Designs for Six Sigma”
BREAKTHROUGH IMPROVEMENT AND BREAKTHROUGH IMPROVEMENT AND INNOVATIVE DESIGN ORIGINSINNOVATIVE DESIGN ORIGINS
BREAKTHROUGH IMPROVEMENT AND BREAKTHROUGH IMPROVEMENT AND INNOVATIVE DESIGN ORIGINSINNOVATIVE DESIGN ORIGINS
Global Leaders in their fields
Genrich Saulovich AltshullerFather of TRIZ
Dr. Joseph M. JuranFather of Breakthrough
Improvement
OUR CREDIBILITY AND OUR CREDIBILITY AND EXPERIENCEEXPERIENCE
OUR CREDIBILITY AND OUR CREDIBILITY AND EXPERIENCEEXPERIENCE
A 23-year successful Juran track record in achieving bottom-line results through pragmatic and systematic implementation of quality management and breakthrough methodologies for our clients.
The Juran-Ideation partnership creates from the strengths and capabilities of two industry leaders a synergistic offering of Innovation and Six Sigma Performance.
A proven, comprehensive business approach, “strategic and tactical” due to the depth and breadth of the full-time Juran Institute staff and services that are unsurpassed by our competitors.
Juran Institute DFSS training and consulting materials are experience-based, translated in multiple languages. Many of our materials are basic
references which are used by clients, universities and other consultants. The DFSS-TRIZ Integration is a unique offering in the industry.
Ideation established 1992Ideation established 1992
Merged with Kishinev School (Leading TRIZ School in Russia)Merged with Kishinev School (Leading TRIZ School in Russia)
Headquarters in Southfield, MI Headquarters in Southfield, MI
85% of the world’s leading TRIZ Scientists85% of the world’s leading TRIZ Scientists
Installed customer base of over 2,000 enterprises worldwideInstalled customer base of over 2,000 enterprises worldwide
Active in 40 countries and 65 universities plus numerous partnerships, strategic alliances and resellers Active in 40 countries and 65 universities plus numerous partnerships, strategic alliances and resellers established worldwideestablished worldwide
IDEATION INTERNATIONAL INC.IDEATION INTERNATIONAL INC.
Ideation International is a world-class provider of accelerated education, innovation software tools,
and analytical services based upon the Ideation/TRIZ Methodology, to enterprises of all
types and sizes.
By understanding the mechanisms that create change, providing the means for recognizing how
to adjust to change, and bringing the essential benefits of innovation, creativity and knowledge to
enterprises, Ideation will achieve its mission.
IDEATION’S MISSIONIDEATION’S MISSION
WHAT IS IDEATION’S WHAT IS IDEATION’S
BUSINESS?BUSINESS?
Inventive Problem Solving
FailureAnalysis
FailurePredictionA
ntic
ipat
ory
Fail
ure
Det
erm
inat
ion
Education Software PublicationsAnalyticalServices
BooksPapers
BookPapers
54 yrs
22 yrs
22 yrs
12 yrsDirected
Evolution PapersUnder
Development
Provider of I-TRIZ:
Age of Application
JURAN INSTITUTE’S MISSIONJURAN INSTITUTE’S MISSION
Our mission is to provide Our mission is to provide professional consulting services to professional consulting services to
improve improve continuously continuously the performance the performance of our clients’ processes, products, of our clients’ processes, products,
people, and profitspeople, and profits..
JURAN INSTITUTEJURAN INSTITUTE
Founded 22 years ago by Dr. J. M. Juran.Founded 22 years ago by Dr. J. M. Juran.Leading source world-wide for research, consulting, and Leading source world-wide for research, consulting, and education in managing for Six Sigma quality to achieve education in managing for Six Sigma quality to achieve superior business results.superior business results.Six Sigma Quality is one of our key businesses today. In Six Sigma Quality is one of our key businesses today. In the present and future, like the past, we have built on our the present and future, like the past, we have built on our competencies - like our competitors. One difference, the competencies - like our competitors. One difference, the Juran Quality Model is the heart of Six Sigma.Juran Quality Model is the heart of Six Sigma.High quality (high sigma values) reduces costs, increases High quality (high sigma values) reduces costs, increases revenues, creates loyal customers and a great culture.revenues, creates loyal customers and a great culture.Not all Six Sigma providers are alike. Juran Institute tries Not all Six Sigma providers are alike. Juran Institute tries to adapt and be flexible in meeting local site requirements, to adapt and be flexible in meeting local site requirements, as well as corporate goals.as well as corporate goals.
WHAT ARE JURAN INSTITUTE’S WHAT ARE JURAN INSTITUTE’S
SERVICES AND PRODUCTS?SERVICES AND PRODUCTS?
Breakthrough Problem Solving
Training E-learning PublicationsConsulting
Services
BooksPapers
BooksPapers
N/AStrategic
Deployment PapersUnder
Development
Provider of Breakthrough Licensing
Design for Six Sigma
DMAIC Six Sigma UnderDevelopment
I- DESIGN FOR SIX SIGMA…I- DESIGN FOR SIX SIGMA…DEFINEDDEFINED
I-DFSS – I-DFSS – – The The Concurrent Development and Introduction Concurrent Development and Introduction of a new or of a new or
radically redesigned product or service and all of the radically redesigned product or service and all of the processes (Design, Procurement, Production, Logistics and processes (Design, Procurement, Production, Logistics and Distribution, Service and Sales) that enable the product or Distribution, Service and Sales) that enable the product or service to achieve Six Sigma business performance.service to achieve Six Sigma business performance.
– A Phased A Phased MethodologyMethodology which includes both the design tools which includes both the design tools and innovative I-TRIZ tools for designing products (goods, and innovative I-TRIZ tools for designing products (goods, information or services) and processes that generate information or services) and processes that generate customer value.customer value.
The phases are The phases are DDefine, efine, MMeasure, easure, AAnalyze, nalyze, DDesign, esign, VVerifyerify
I-DFSS:I-DFSS:New Product/Service Introduction to Achieve Six New Product/Service Introduction to Achieve Six
Sigma Business PerformanceSigma Business Performance
I-DFSS:I-DFSS:New Product/Service Introduction to Achieve Six New Product/Service Introduction to Achieve Six
Sigma Business PerformanceSigma Business Performance
MARKETRESEARCH
MARKETRESEARCH
DESIGNDESIGN
PRODUCTIONPRODUCTION
LOGISTICSLOGISTICS
DISTRIBUTIONDISTRIBUTION
SERVICESERVICE
SALESSALES
DMADV
INNOVATIVE DESIGNS FOR INNOVATIVE DESIGNS FOR SIX SIGMA…DEFINED SIX SIGMA…DEFINED
CUSTOMERSCUSTOMERSCUSTOMERSCUSTOMERS
Customer-driven design of processes with 6 capability.
Predicting design quality up front.
Top down requirements flowdown (CTQ flowdown) matched by capability flowup.
Cross-functional integrated design involvement.
Drives quality measurement and predictability improvement in early design phases.
Utilizes process capabilities to make final design decisions.
Monitors process variances to verify 6 customer requirements are met.
WHAT IS DESIGN FOR SIX WHAT IS DESIGN FOR SIX SIGMA (DFSS)?SIGMA (DFSS)?
THE DMADVTHE DMADVMETHODOLOGY AND TOOLSMETHODOLOGY AND TOOLS
Define Measure Analyze Design Verify
Under-standcustomerneeds andspecifyCTQs
Developdesignconceptsand high-level design
Developdetaileddesign andcontrol/testplan
Testdesign andimplementfull-scaleprocesses
Initiate, scope,and plan theproject
DESIGN FOR SIX SIGMA
DELIVERABLES
TeamCharter
CTQs High-levelDesign
DetailedDesign
Pilot
TOOLS
Mgmt Leadership Customer ResearchFMEA/Errorproofing
Project QFD Process SimulationManagement Benchmarking Design Scorecards
Commercial ElectronicsCommercial Electronics
South Korea based company-wide implementation of Six Sigma, including South Korea based company-wide implementation of Six Sigma, including
South Korea, Hungary, India, Indonesia, Malaysia, Mexico, Spain, United South Korea, Hungary, India, Indonesia, Malaysia, Mexico, Spain, United
Kingdom and United States.Kingdom and United States.
SOME OF OUR CLIENTS...SOME OF OUR CLIENTS...
Satellite ManufacturerSatellite Manufacturer
Implemented Design for Six SigmaImplemented Design for Six Sigma
SOME OF OUR CLIENTS...SOME OF OUR CLIENTS...
GMGM
FordFord
ToyotaToyota
ChryslerChrysler
EatonEaton
Dana CorporationDana Corporation
Rockwell Int’l AutomotiveRockwell Int’l Automotive
TRW AutomotiveTRW Automotive
ITT AutomotiveITT Automotive
JaguarJaguar
Cost reduction, warrantees, recalls, new design, patent circumvention, failure analysis, failure prediction, training
Break squealBreak squeal
Brake roughnessBrake roughness
Noise and vibrationNoise and vibration
TransmissionTransmission
Air bagAir bag
Electrostatic paintElectrostatic paint
Tail lightTail light
Seat coverSeat cover
Wind tunnelWind tunnel
Plastic fuel tankPlastic fuel tank
IDEATION’S SUCCESSES-TO-DATE:IDEATION’S SUCCESSES-TO-DATE:AUTOMOTIVE INDUSTRYAUTOMOTIVE INDUSTRY
DowDow
AmocoAmoco
DupontDupont
ConocoConoco
SolutiaSolutia
Rohm & HaasRohm & Haas
Cost reduction, breakthrough/discovery, manufacturing processes, safety, quality, reliability, failure analysis
PlasticsPlastics
Chemical processingChemical processing
CatalystsCatalysts
ReactorReactor
Aromatic oxidationAromatic oxidation
Distillation/separationDistillation/separation
New material New material development/designdevelopment/design
IDEATION’S SUCCESSES-TO-DATE:IDEATION’S SUCCESSES-TO-DATE:CHEMICAL INDUSTRYCHEMICAL INDUSTRY
ExxonExxon
MobilMobil
AmocoAmoco
ShellShell
Cost reduction, reliability, failure analysis, new design, training
ExplorationExploration
Method of discoveryMethod of discovery
RefineriesRefineries
Post processingPost processing– GasGas– Fuel oilFuel oil
Enhanced oil recoveryEnhanced oil recovery
Dual grading drillingDual grading drilling
Expandable casingExpandable casing
Hydro carbon processingHydro carbon processing– on shoreon shore– off shoreoff shore
TransportationTransportation
IDEATION’S SUCCESSES-TO-DATE:IDEATION’S SUCCESSES-TO-DATE:OIL INDUSTRYOIL INDUSTRY
Johnson & JohnsonJohnson & Johnson
CardiovascularCardiovascular
RocheRoche
Bristol MyersBristol Myers
Zeneca (UK)Zeneca (UK)
New design, patent circumvention, cost reduction, failure prediction, training
Medical instrumentationMedical instrumentation
Sanitary productsSanitary products
Blister packaging of pillsBlister packaging of pills
IDEATION’S SUCCESSES-TO-DATE:IDEATION’S SUCCESSES-TO-DATE:MEDICAL INDUSTRYMEDICAL INDUSTRY
HoneywellHoneywell
MotorolaMotorola
Philips ElectronicsPhilips Electronics
HitachiHitachi
ITTITT
Arteche (Spain)Arteche (Spain)
VisteonVisteon
Northern Telecon (Canada)Northern Telecon (Canada)
SolarexSolarex
HelixHelix
ToshibaToshiba
SonySony
LG ElectronicsLG Electronics
Cost reduction, new technologies, reliability, manufacturing processes, training
Cell phonesCell phones
MicrochipsMicrochips
PC boardsPC boards
RadioRadio
HeadsetHeadset
High voltage transformersHigh voltage transformers
Power suppliesPower supplies
Navigation systemsNavigation systems
IDEATION’S SUCCESSES-TO-DATE:IDEATION’S SUCCESSES-TO-DATE:ELECTRONICS/ELECTRICAL INDUSTRYELECTRONICS/ELECTRICAL INDUSTRY
BoeingBoeing
Pratt & WhitneyPratt & Whitney
Techspace Aero (Belgium)Techspace Aero (Belgium)
HoneywellHoneywell
Allied SignalAllied Signal
Rockwell InternationalRockwell International
Rolls RoyceRolls Royce
McDonnel Douglas AerospaceMcDonnel Douglas Aerospace
NASANASA
Hughes AircraftHughes Aircraft
TRWTRW
BF GoodrichBF Goodrich
LittonLitton
Cost reduction, safety, reliability, quality, new design, failure analysis and prediction, training
C-17C-17
F-22F-22
EnginesEngines
ValvesValves
Containment ringContainment ring
IDEATION’S SUCCESSES-TO-DATE:IDEATION’S SUCCESSES-TO-DATE:AVIATION INDUSTRYAVIATION INDUSTRY
I-DFSS DESIGN PROJECTI-DFSS DESIGN PROJECTCASE 1CASE 1 CASE 2CASE 2 CASE 3CASE 3
Base Line Performance OK
CurrentProduct
CurrentProduct
DPMOCOPQ
DesignDesign
CurrentProcesses
ManufacturingManufacturing
DistributionDistribution
ServiceService
MarketingMarketing
REDESIGN
Cp, CpkCOPQ
DPMOCOPQ
CurrentProduct
CurrentProduct
NewProcesses
NEW PROCESS DESIGN
Product Base Line Performance OK(May be of little value)
NewProduct
NewProduct
NewProcesses
NEW PRODUCT ANDPROCESS DESIGN
No Base Line Performance
CTQ’sCTQ’s
High-level Design
High-level Design
CTQ GAP“Base Line
Performance”
CTQ GAP“Base Line
Performance”
DesignScorecard
DesignScorecard
But:
No Current Product or Process
DesignDesign
SCIENTIFICALLY BASED APPLICATIONS: SCIENTIFICALLY BASED APPLICATIONS: SYSTEMATIC, STRUCTURED INNOVATIONSYSTEMATIC, STRUCTURED INNOVATION
IPS
DE
AFD
InventiveInventiveProblemProblemSolvingSolving
AnticipatoryAnticipatoryFailureFailure
DeterminationDetermination
Directed EvolutionDirected Evolution
FailureAnalysis
FailurePrediction
Strategically Evolving Future Generations of Technologies & Systems
Surgical Removal of Tough Technological Problems
Invention of Failure Modes Elimination of Contradictions
I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA
Pre-DEFINE PhasePre-DEFINE Phase
– INTRODUCTION TO SIX SIGMAINTRODUCTION TO SIX SIGMA– HOW TO THINK ABOUT DFSS/NEW PRODUCT HOW TO THINK ABOUT DFSS/NEW PRODUCT
INTRODUCTION (NPI)INTRODUCTION (NPI)– I-TRIZ/Directed Evolution (DE)I-TRIZ/Directed Evolution (DE)
Strategic visionStrategic visionLogical chain of product conceptsLogical chain of product conceptsProduct evolution roadmapProduct evolution roadmap
DEFINE PhaseDEFINE Phase
– INTRODUCTION TO DEFINEINTRODUCTION TO DEFINE– ESTABLISH DESIGN PROJECTESTABLISH DESIGN PROJECT– FINANCIAL ANALYSISFINANCIAL ANALYSIS– PROJECT MANAGEMENT AND RISK PROJECT MANAGEMENT AND RISK
ASSESSMENTASSESSMENT– SUMMARY; ISSUES TO CONSIDERSUMMARY; ISSUES TO CONSIDER
I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA
MEASURE PhaseMEASURE Phase– INTRODUCTION TO MEASUREINTRODUCTION TO MEASURE– ESTABLISH CTQ’s AND CTI’sESTABLISH CTQ’s AND CTI’s– I-TRIZ/Innovation Situation Questionnaire & Problem FormulatorI-TRIZ/Innovation Situation Questionnaire & Problem Formulator
Design problem documentationDesign problem documentationDesign expectationsDesign expectations
– INTRODUCTION TO PROBABILITY, STATISTICS AND PREDICTIONINTRODUCTION TO PROBABILITY, STATISTICS AND PREDICTION– MSA (Variables, Attribute and Data quality)MSA (Variables, Attribute and Data quality)– PROCESS CAPABILITY (Variables and Attribute)PROCESS CAPABILITY (Variables and Attribute)– RISK ASSESSMENTRISK ASSESSMENT– I-TRIZ/Anticipatory Failure Determination (AFD)I-TRIZ/Anticipatory Failure Determination (AFD)
Failure predictionFailure prediction
– DESIGN SCORECARDDESIGN SCORECARD
I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA
ANALYZE/HIGH-LEVEL DESIGN PhaseANALYZE/HIGH-LEVEL DESIGN Phase– INTRODUCTION TO HIGH-LEVEL DESIGNINTRODUCTION TO HIGH-LEVEL DESIGN– DEVELOP DESIGN ALTERNATIVESDEVELOP DESIGN ALTERNATIVES– I-TRIZ/Innovative Problem Solving (IPS)I-TRIZ/Innovative Problem Solving (IPS)
Description of design options (alternatives)Description of design options (alternatives)Analysis of design alternatives for technological barriers and Analysis of design alternatives for technological barriers and contradictionscontradictions
– DEVELOP HIGH-LEVEL DESIGN (VA/VE)DEVELOP HIGH-LEVEL DESIGN (VA/VE)– MULTI-VARI ANALYSISMULTI-VARI ANALYSIS– CONFIDENCE INTERVALS AND SAMPLINGCONFIDENCE INTERVALS AND SAMPLING– HYPOTHESIS TESTING AND ANOVAHYPOTHESIS TESTING AND ANOVA– EVALUATE HIGH-LEVEL DESIGNEVALUATE HIGH-LEVEL DESIGN– I-TRIZ/Anticipatory Failure Determination (AFD)I-TRIZ/Anticipatory Failure Determination (AFD)
Failure analysis and prediction Failure analysis and prediction
I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA
DETAIL DESIGN PhaseDETAIL DESIGN Phase
– INTRODUCTION TO DESIGNINTRODUCTION TO DESIGN– RISK ASSESSMENT/FALURE ANALYSISRISK ASSESSMENT/FALURE ANALYSIS– I-TRIZ/Anticipatory Failure Determination I-TRIZ/Anticipatory Failure Determination
(AFD)(AFD)Failure analysisFailure analysis
– TAGUCHI METHODS AND ROBUST DESIGNTAGUCHI METHODS AND ROBUST DESIGN– TOLERANCINGTOLERANCING– DOE with RSMDOE with RSM
I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA
DETAIL DESIGN Phase (cont’d)DETAIL DESIGN Phase (cont’d)
– RELIABILITY and AVAILABILITYRELIABILITY and AVAILABILITY– NON-PARAMETRIC STATISTICS NON-PARAMETRIC STATISTICS – SIMULATION with Monte Carlo MethodsSIMULATION with Monte Carlo Methods– DESIGN FOR MANUFACTURABILITY/DESIGN DESIGN FOR MANUFACTURABILITY/DESIGN
FOR ASSEMBLYFOR ASSEMBLY– DVT/TESTABILITYDVT/TESTABILITY– DESIGN SCORECARDDESIGN SCORECARD
I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA
DETAIL DESIGN Phase -- CUSTOM FEATURESDETAIL DESIGN Phase -- CUSTOM FEATURES
– THE TOOLS OF DETAIL DESIGNTHE TOOLS OF DETAIL DESIGN– CONCURRENT ENGINEERINGCONCURRENT ENGINEERING– SOFTWARE ENGINEERING METHODS AND TOOLS SOFTWARE ENGINEERING METHODS AND TOOLS
(CMM, CASE)(CMM, CASE)ENHANCED DESIGN FOR:Commercial/Competitive SuccessManufacturabilityServiceabilityReliabilityAvailabilityInformation ManagementControl
I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA
VERIFY PhaseVERIFY Phase– INTRODUCTION TO VERIFYINTRODUCTION TO VERIFY– DESIGN FOR CONTROLDESIGN FOR CONTROL– DESIGN FOR MISTAKE- AND FOOLPROOFINGDESIGN FOR MISTAKE- AND FOOLPROOFING– STATISTICAL PROCESS CONTROL (SPC)STATISTICAL PROCESS CONTROL (SPC)– MVTMVT– TRANSITION TO PROCESS OWNERSTRANSITION TO PROCESS OWNERS– I-TRIZ/Directed Evolution (DE)I-TRIZ/Directed Evolution (DE)
Logical sequence of new scenariosLogical sequence of new scenariosStrategic knowledge base and patent portfolioStrategic knowledge base and patent portfolioTargeted competitive intelligenceTargeted competitive intelligenceNew product evolutionary stagesNew product evolutionary stages
– SUMMARY; ISSUES TO CONSIDER; PROJECT CLOSURESUMMARY; ISSUES TO CONSIDER; PROJECT CLOSURE
I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA
VERIFY Phase -- CUSTOM FEATURES VERIFY Phase -- CUSTOM FEATURES
– PILOT TESTINGPILOT TESTING– FULL-SIZE SCALE-UP AND FULL-SIZE SCALE-UP AND
COMMERCIALIZATIONCOMMERCIALIZATION– DESIGN INFORMATION AND DATA DESIGN INFORMATION AND DATA
MANAGEMENTMANAGEMENT– LEAN MANUFACTURINGLEAN MANUFACTURING
I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA
D-M A D V
15 - 16 Weeks
Training
Weeks
Project
1 3 1 4 1 4 - 6 1 4 - 6
IDEAL
VDR-3DDR-2APPD-M
DVT MVT
DR-4
19 - 22 Weeks(5-6 Months)Critical Success Factors:
• Project starts with training• Project < 6 months• Project phases match training schedule
DMADV Training/Project Map DMADV Training/Project Map
I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA
TrainingProject
(D)
Mass Production
Training(B)
(C)
(A) ?
OK
?
No
Start
REAL
DR-2
Start
DR-3
GapStart
Start
Project
Training
Training
Consulting
Product Planning Project
Project
D-M
DMADV Training/Project Map DMADV Training/Project Map
I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA
Executive Briefing
Preparations
Champion Training/Workshop
Go-No go Decision
Master Black Belt ProgramMaster Black Belt Program
Trained Black Belt
CertificationProject
CertifiedBlack Belt
Black Belt TrainingBlack Belt Training
Define/Measure
Analyze
Design
Verify
D/M
A
D
V
Black Belt ProjectBlack Belt Project
Master BlackBelt Project
Certified MBBs
Statistics, Finance
Leadership Skills
2 days
4-8 hrs JURAN
Sr. Instructor
JURAN
Sr. Instructor
JURAN
INSTRUCTOR(first wave)
Total Duration:4-6 months
Total Duration:4-6 months
JURAN
Sr. INSTRUCTOR
Yes
No?
SIX SIGMA DMADV TRAINING FLOWSIX SIGMA DMADV TRAINING FLOW
DMADVDMADV