Design for Six Sigma Black Belt Programme

Introduction:

Design for Six Sigma (DFSS) is an emerging process management methodology related to traditional Six Sigma. While Six Sigma methodology targets breakthrough improvement of an existing manufacturing or service process (as part of a bigger picture of continuous process improvement), DFSS seeks to avoid manufacturing/service defects at the outset by improving the design process during the initial system/product development phase. In short, DFSS aims to build the efficiencies of Six Sigma methodology into the design process before the implementation phase. The desired outcome of DFSS is a system/product solution that increases product and service effectiveness in the eyes of the customer, leading to greater customer satisfaction and market share.

DFSS integrates the tools application systematically into an IDOV (Identify, Design, Optimize & Validate) roadmap, essentially deploying the best practices in VOC & systems engineering into the design process. When effectively executed, the IDOV roadmap brings an organization closer to achieving ‘Six Sigma’ levels of performance by ‘designing in’ these expectations into the system/product development process.

This 20-day training workshop is organized into 4 phases (IDOV phases) spanning an 8-week period. Participants are required to work in teams on real, mid-scale DFSS projects during the workshop to aid learning. Each week (or phase) of workshop consists of 2 to 5 days of classroom training followed by on-site project execution for the remainder of the training phase to apply the techniques learnt. At the beginning of the next phase, participants are required to present their project progress of the previous phase.

By the end of the workshop, participants will have gained a deep insight of DFSS as a business strategy and learnt how to apply it comprehensively on a DFSS project. By completing the DFSS projects at the end of training, participants will have demonstrated a high level of competency in applying many of the DFSS techniques, in project management and in DFSS Scorecard management. The workshop ends with participants understanding the responsibilities of a DFSS Black Belt and its leading role in the steering of a system/product development project.

Duration: 20 Days

Target Audience:

Managers, senior design engineers, quality managers, senior reliability engineers in the Design Engineering, R&D, Continuation Engineering, etc. functions, preferably with minimum 2 years of work experience and certified as Six Sigma Green Belts.

Programme Objectives:

This interactive workshop will groom participants to be DFSS Black Belts with a proficient knowledge of key DFSS techniques to apply to small-scale DFSS projects as part of a system/ product development project. At the end of the workshop, participants will be able to:

• Understand the concept & principles of DFSS as a business strategy
• Apply the key DFSS techniques on a DFSS project using the IDOV roadmap
• Demonstrate practical application of DFSS through real DFSS team-projects
• Appreciate the responsibilities of a DFSS Black Belt and its role in the requirements management process of a system/product development project

Programme Content:

Identify Phase
- Introduction to DFSS
- Voice of the Customer
- Project Charter
- Quality Function Deployment
- Strategic Planning and Project Definition
- On-Site Project Application

Design Phase
- Identify Phase Project Review
- TRIZ & Design Alternatives
- Design for Assembly & Manufacturability
- Design Selection using Pugh/SDI Matrix
- Design FMEA
- Review of Hypothesis Testing
- Statistical Modeling with Design of Experiment (DOE)
. Factorial DOE (Full and Fractional)
. Robust DOE and Taguchi Methods
. Sample Size Determination
. Response Surface Methodology
- Statistical Modeling with Linear Regression
- Measurement System Analysis
- On-Site Project Application

Optimize Phase
- Design Phase Project Review
- Sensitivity Analysis
- Monte Carlo Simulation
- Statistical Tolerance Allocation
- Multi-Optimization
- Capability Score (Short-Term)
- On-Site Project Application

Validate Phase
- Optimize Phase Project Review
- Reliability and Accelerated Life Testing
- Error-Proofing for Process/Design
- SPC & Control Plans
- Requirements Management and DFSS Scorecard
- On-Site Project Application
Project Review
Assessment

Contact Us

This is a customised programme. Please contact Kaizen Consulting Group for more information and programme customisation:

Email: 
Tel: (65) 68484109

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