Design For Six Sigma Methodology Research Articles

Roadmap for product development based on design for six sigma method

Purpose The Design For Six Sigma (DFSS) methodology is one of the most important to achieving excellence in an organization’s product development process. This paper aims to propose a roadmap for product development based on the DFSS for the consumer durables manufacturing industries. The proposed roadmap presents a systematic approach to the phases of the product development process, integrating the statistical techniques and quality tools that should be used in each phase. Design/methodology/approach This study presents a detailed roadmap for product development, which was built by identifying gaps in the DFSS methods, based on previous studies on the subject. In this step, the opportunities are provided in all phases from creation to discontinuation of the product in the market. In addition, the roadmap presented was validated by team of stakeholders in the product development process of different industrial companies. Findings The proposed roadmap for the product development process based on six sigma design suggests a visual tool with sequential steps and techniques that allow you to follow the evolution of the development process from idea conception until the product is discontinued in the market. Identifying the priorities of organizations, especially the consumer, regarding the quality and reliability of the product. Practical implications The roadmap seeks to facilitate an understanding of the important stages of the product development process and to provide an approach to improving and optimizing the product before the manufacturing process step through the principles of DFSS methodology. This research provides a guide step by step to apply statistical techniques and quality tools in the product development process to achieve high quality and six sigma level in the manufacturing process. Originality/value The proposed roadmap of this research combines design for sigma and product development concepts, covering a wide spectrum of relevant activities that include the product development process, the application of statistical techniques and the design of high-quality durable consumer goods to match manufacturing technologies.

Design for Six Sigma: A Review of the Definitions, Objectives, Activities, and Tools

This paper presents a theoretical review of the definitions, objectives, activities, and tools applied in the Design for Six Sigma (DFSS) methodology. It also proposes a theoretical framework that provides a simplified and generic guide, which is not easily found in the scientific literature. The methodology used consists of 3 phases: (a) Systemic review, structured to search and select references on DFSS after 2009; (b) Selection of specific books on DFSS that were cited in the studies found in the systematic review (step “a”); (c) Application of the Bibliometrix scientific mapping tool. Seventeen definitions and objectives of DFSS were enumerated; 9 sets of DFSS structuring phases were observed; a list with 54 main activities and 72 tools that can be applied in DFSS was generated. This proposal aims to bring the DFSS methodology closer to the practical actions of engineering management.

Smart Cane Developed with DFSS, QFD, and SDE for the Visually Impaired

This study shows an application of the Design for Six Sigma (DFSS) Methodology in the field of medical engineering. This research aims to demonstrate the application of a systematic design approach in the development of the “Ocane”, an innovative concept of smart cane for visually impaired patients which was thought of in answer to the end user’s needs, deploying an easy to transport, locate, and adjust element with ultrasonic sensors and tactile feedback. DFSS is an analytical design methodology meant to organize project workflow in a sequence of specific steps. Other standardized design procedures such as Quality Function Deployment (QFD) and Stylistic Design Engineering (SDE) have been used to support DFSS in terms of targeting customer requirements and focusing on aesthetics for ergonomics analysis, respectively. First, the QFD process is introduced and applied to gather the final customer needs, completing the analysis with benchmarking and similar-thought products on the market. Afterwards, a description of the DFSS methodology and application to the case study was deployed. Thereafter, the SDE procedure is exposed by identifying the “Ocane” concept and development, and moving towards the completion of an inventive product with a creative design and careful attention to visually impaired clients’ requirements.

Ten commandments for successful implementation of Design for Six Sigma

PurposeThis article aims to provide Design for Six Sigma (DFSS) practitioners, researchers and academicians with Ten Commandments to successfully deploy projects.Design/methodology/approachThe commandments are the brainchild of four authors' experience and expertise for more than 15 years of DFSS deployment in the spectrum of fields as a consultant, researcher, academic and Master Black Belt in Six Sigma and general quality management and engineering disciplines. Thus ascertained commandments were validated and classified through the “Delphi Study” to ensure its applicability.FindingsThe Ten Commandments from authors' perspective include: alignment of DFSS with organisational strategy; top management support and involvement; listening to the voice of the customers (VOC); effective training programme for right project teams; project selection and prioritisation; linking DFSS with ISO international standards; linking DFSS with organisational learning and innovation; linking DFSS with the 4th Industrial Revolution; effective use of DFSS methodology and the integrated tools within the methodology and reward and recognition schemes.Research limitations/implicationsThe commandments presented in this article are the authors' personal experience in different industrial scenarios and settings and demographical locations. The authors are planning to conduct a longitudinal survey to understand further insights of these commandments with the input of several DFSS Black Belts and Master Black Belts, academicians and leading researchers from various countries.Originality/valueAll the organisation's stakeholders can use this article as general guidelines to ensure effective deployment of the DFSS approach.

Design for six sigma integrated product development reference model through systematic review

PurposeThis paper aims to present a systematic review of design for six sigma (DFSS) methods applicable to the product development process (PDP) of durables goods and identify a research opportunity on the subject proposing integration of DFSS and a reference model for the PDP. In this way, through the analysis of the theoretical references identified in the scientific databases, it was possible to propose a conceptual model for the PDP oriented to the DFSS.Design/methodology/approachThis paper is based on the theoretical framework presented in peer-reviewed scientific research papers during the period 2000 to 2018 on the theme DFSS applied in the PDP, as well as such as the product development tools/techniques and statistics addressed. By means of key words defined by the acronyms of DFSS methods (DMADOV, ICOV, DMEDI, IDOV, DDOV, PIDOV, DMADIC, DCCDI, DMADV, IDDOV, CDOV and DCOV), DFSS and the acronym DFSS. Applying Boolean expression during the conduction of the searches through the scientific evidence at the Brazilian scientific database platform (Capes database). This database platform is maintained by coordination for the improvement of higher education personnel, which including Emerald Insight (Emerald), Scopus (Elsevier), Science Direct, SpringerLink, Taylor Francis, Scielo (Web of Science), Wiley Online Library, Web of Science (Clarivate Analytics), etc. It was obtained, by means of the searches, 269 papers related to subject DFSS, of which 18 papers had been critically selected for the composition of a conceptual model for the process of development of product guided to the DFSS.FindingsThis study presents a review of the literature (systematic review and content analysis) on DFSS and its effectiveness for the PDP. The DFSS methodology is disseminated in the scientific literature through a variety of methods that are often mistaken for the six sigma methodology – DMAIC, which is directed toward process improvement. The PDP integrated with the DFSS concepts contributes to eliminating possible failures during the design of a new product, directing to reduce costs and improve the quality of the product and process.Practical implicationsThis paper presents a literature review that guided to a proposal of a preliminary conceptual model DFSS focused on the process of product development with the purpose of being a friendly model that meets the dynamics of the organizations and the expectations of the consumers.Originality/valueThrough the systematic review and content analysis, it was possible to observe that the DFSS methods applied to product development are not related to the PDP reference models available in the literature. In this way, the fusion of the concepts of the DFSS methods and PDP reference models for the construction and proposition of a preliminary conceptual model DFSS oriented to the process of product development intends to contribute in the development of new products with the reduction of time, reduction of the cost, competitive price and consumer satisfaction.

Robust Design of an Outer Rotor Permanent Magnet Motor Through Six-Sigma Methodology Using Response Surface Surrogate Model

There is always uncertainty in industrial manufacturing. These uncertainties have an undesirable impact on the products if deterministic optimization approaches are employed. In order to have products as desired, uncertainties must be quantified in the design process. This paper presents a robust design optimization of an outer rotor surface mounted permanent magnet motor with particular application in the hybrid vehicle using the design for six-sigma methodology. Due to very long computational time of robust optimization, a ten high-dimensional surrogate model of the system using the Box-Behnken response surface methodology (RSM) is integrated with the particle swarm optimization (PSO). This causes a significant improvement in the effectiveness and efficiency of optimization. The results acquired from RSM are verified by their simulation using the finite-element method, and the accuracy of RSM is proved. Finally, the deterministic and robust optimized motors are simulated in mass production using Monte Carlo analysis, and six-sigma quality achievements are demonstrated.

Combustion System Design of a Genset Diesel Engine by Using DFSS Methodology

In this study, an optimum design for the combustion system of a genset diesel engine was conducted by using Design for Six Sigma (DFSS) methodology. As a result of this study, the best combination of design parameters to minimize the fuel consumption of the genset diesel engine was selected while meeting the requirements of NOx emission and peak firing pressure (PFP) limit. Compared to the initial design, the final design proposal has achieved 2.5 % and 1.6 % improvement in brake specific fuel consumption (BSFC) at switchable operating conditions, i.e., both 1500 and 1800 rpm. On the basis of this DFSS work, the design robustness was also enhanced. Hence, it is expected that the final design proposal would reduce the variability in fuel economy that could be caused by harsh environment and system aging. In this study, engine cycle simulation technique was employed to assess the effects of various design parameters on the performances of the genset diesel engine. The current optimum design work has considered four control factors such as turbocharger size, air temperature at charge air cooler (CAC) outlet, compression ratio, and fuel injection duration. Here, an L9 orthogonal array was used to efficiently choose the best design proposal among 81 design combinations (i.e., four independent control factors which individually have three different levels).

Optimum design for intake and exhaust system of a heavy-duty diesel engine by using DFSS methodology

In this study, an optimum design for intake and exhaust system of a heavy-duty diesel engine was conducted by using the well-known design for six sigma (DFSS) methodology. As a result of this work, the NOx emission regulation has been successfully satisfied while minimizing the fuel consumption. On the basis of this DFSS work, the design robustness of the engine system was also enhanced. Hence, it is expected that the final design proposal would reduce the variability in brake thermal efficiency (BTE) that could be caused by the harsh environment and the system aging. Especially, this work has successfully raised the amount of exhaust gas recirculation (EGR) up to the target level by adopting the venturi tubes in the intake and exhaust lines. In this study, engine cycle simulation technique was employed to assess the effect of the various design parameters and the final design proposal was verified through a real engine test. The current optimum design work has considered four control factors such as the size of turbocharger, the diameter of intake and exhaust venturi pipes, and the efficiency of EGR cooler. Here, an L9 orthogonal array was employed to efficiently choose the best design proposal among 81 design combinations (i.e., four independent control factors which individually have three different levels).

Utilizing Kaizen process and DFSS methodology for new product development

PurposeThe purpose of this paper is to propose a new framework for early design stage utilizing the benefits of Kaizen events, and Design for Six Sigma (DFSS) methodology. To gain a better understanding of the proposed method, a case study of a diesel engine development was presented where the proposed methodology was followed.Design/methodology/approachThis paper proposes a hybrid Kaizen DFSS methodology consisting of four Kaizen milestone events with pre-work preceding these events. The events are in line with the four phases of DFSS methodology (define, characterize, optimize, and verify).FindingsIn order for the proposed method to succeed, few key enablers should be available such as management buy-in and support, effective resources utilization, and proper planning. However, this methodology should be utilized for key projects where criticality is high and deadlines are nearby.Practical implicationsAs proved by two projects, one of them is presented in this paper; the use of the proposed methodology is effective and can bring significant positive changes to an organization.Originality/valueAlthough Kaizen is an old and well-known process, it is to the best of the author’s knowledge that Kaizen has not been utilized in the early design stages of new product development projects. In this paper, a hybrid methodology combining traditional DFSS systematic approach conducted using Kaizen improvement events is proposed and supported by a real-life case study.

Designing a Test Fixture with DFSS Methodology

This paper addresses the application of Design for Six Sigma (DFSS) methodology to the design of a marine riser joint hydraulic line test fixture. The original test fixture was evaluated using Value Steam Mapping (VSM) and appropriate Lean design tools such as 3D Modeling and Finite Element Analysis (FEA). A new test fixture was developed which resulted in improving the process cycle efficiency for the test from 25% to 50% percent, leading to a 50% reduction in test cost. Handling of the new test fixture is greatly improved as compared to the original fixture.

항공 산업의 DFSS 적용방법에 관한 연구

Purpose: In this paper, a Design for Six Sigma(DFSS) methodology based on DMADV(Define-Measure-Analyze-Design-Verify) roadmap is presented. Methods: DFSS tools are given for each DMADV phase which is suitable for the aircraft development process. A cost reduction case study of a navigation simulation is demonstrated. Results: DFSS roadmap are presented with implementation tools for each phase. Conclusion: We propose a DFSS methodology which can benefit the design and development personnel to implement DFSS not only in aircraft industry but also in other order-based industries in general.

DFSS 를 이용한 홀 효과 기반 회전형 위치 센서의 설계

본 논문에서는 홀 효과(Hall effect) 기반 회전형 위치 센서의 출력 전압에 대한 선형성 및 민감도를 최적화하기 위해 DFSS(Design for Six Sigma) 방법을 적용하였다. 이를 위해 영구 자석의 치수 및 홀센서에 대한 상대 위치 등을 설계 인자로 하여 완전 요인 배치법을 사용하였다. 설계 인자의 수준별 센서 출력 전압값은 자속 밀도에 대한 Biot-Savart 해석해 및 홀 센서 고유의 자속 밀도-출력 전압에 대한 관계식을 이용하여 구하였다. 최적화된 설계 인자들을 반영하여 제작된 회전형 위치 센서의 개선된 출력 전압 측정 결과를 통해 제안된 방법은 간편하면서 실용적으로도 매우 유용한 방법임을 확인하였다.

A Program Level Application of Design for Six Sigma in the Aircraft Industry

Design for Six Sigma (DFSS) has been implemented in many companies to enhance their business performance and customer satisfaction. However, DFSS has not been widely applied to the aircraft industry which operates large, complex development programs. In this paper, the characteristics of an aeronautical product development program are analyzed to figure out the limitations of current DFSS methodology and the prerequisite to deployment of DFSS at the program level is suggested.

Problem‐based learning approach to application of statistical experimentation

AbstractIn product development, statistical experimentation techniques can help to improve product quality so as to meet or even exceed customers' requirements. To integrate proper statistical techniques effectively and sustainably into new product development and innovation processes, it is important to train product development engineers who are usually experts in their respective engineering domain. In this paper, a problem‐based learning approach integrated within a Design for Six Sigma (DFSS) training program is described. It is illustrated that instead of relying on ad hoc implementation, statistical experimentation introduced through the DFSS methodology would enable product development engineers to appreciate its usefulness within a broader framework. Copyright © 2010 John Wiley & Sons, Ltd.

A systems approach to order fulfilment

Supply chain management aims to add value across the supply chain, and customer service is now a major strategic issue. Supply chains are complex and subject to variables of forecast, supply, process and transportation which can lead to problems, such as the Bullwhip effect, product lateness, damaged goods and stock outs. A key issue that companies are facing today is how to monitor and control performance across the chain. This paper presents design for six sigma (DFSS), which focuses on customer requirements from the onset, as an effective methodology for monitoring and controlling supply chain variables, optimising supply chain processes and meeting customer's requirements. By applying DFSS methodology to the key supply chain process of order fulfilment, a customised representation of detailed activities of order fulfilment processes is demonstrated providing key performance indicators. A theoretical transfer function for predicting the performance of the perfect order incorporating fuzzy set theory provides a way of monitoring supply chain performance.

Improving efficiency and effectiveness of APQP process by using DFSS tools

This study aims at improving the efficiency and effectiveness of the Plan and Define phases (Phase I) of Advanced Product Quality Planning (APQP) process by using appropriate Design for Six Sigma (DFSS) tools in an automotive plant. The main objectives of APQP and Control Plan reference manual are to provide a quality product on time and at the lowest cost, by early identification of changes and thus satisfying the customers. Application of DFSS methodology in APQP makes it more objective, measurable and robust as more and more data are collected and objective evaluation is suggested. The same methodology can be generalised and utilised appropriately at all the other phases of new product and process development phases. This paper also suggests a comprehensive list of tools that can be utilised at all phases of APQP.

Optimizing order fulfillment using design for six sigma and fuzzy logic

Supply chain management aims to add value across the supply chain and customer service is now a major strategic issue. Supply chains are complex and subject to variables of forecast, supply, process, and transportation which can lead to problems such as the bull whip effect, product lateness, damaged goods and stock outs. A key issue facing companies today is how to monitor and control performance across the chain. This paper presents Design for Six Sigma (DFSS), which focuses on customer requirements from the onset, as an effective methodology for monitoring and controlling supply chain variables, optimizing supply chain processes and meeting customer’s requirements. By applying DFSS methodology to the key supply chain process of order fulfillment, a customized representation of detailed activities of order fulfillment processes is demonstrated providing key performance indicators. A theoretical transfer function for predicting the performance of the perfect order incorporating fuzzy set theory provides a way of monitoring supply chain performance.

A Study of Lean DFSS through the Creative Value Design

Six Sigma uses DMAIC (Define, Measure, Analyze, Improve, Control) methodology as the process of a solving problem. Enterprises already propelling Six Sigma successfully, such as Motorola, GE and consulting companies, also traditionally propose DMAIC methodology. But, from activating Six Sigma, enterprises and Six Sigma‐consulting companies propose Six Sigma methodology matching indirection part of office and R&D part. As an exmaple, DFSS (Design For Six Sigma) is part of R&D application in GE. This study investigates Six Sigma methodology corresponding to the Right Process of the kernel factor. Especially for the optimum design of R&D, the study revises the definition of DFSS and the general organization through Lean DFSS methodology research and analysis.