Dfss

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Recent Innovations in Design for Six
Sigma (DFSS) Testing: Approaches to
Speed Technology to the Marketplace

Dr. Mark J. Kiemele
Air Academy Associates

Air
Academy
Associates
Copyright
2005

21st Annual National Test & Evaluation Forum
National Defense Industrial Association
Charlotte, NC
March 10, 2005

Agenda

• Brief Overview of Design for Six Sigma (DFSS)
• FactorialTesting and Sequencing of the Tests
• High Throughput Testing
• Multidiscipline Design Optimization with
Latin Hypercube Sampling

Air
Academy
Associates
Copyright
2005

1

Six Sigma Defined
Originally: Metric Based on the Statistical Measure Called
Standard Deviation
Expanded To:
WORLD CLASS QUALITY
Providing a
BETTER product or service,

Low
Spec

High
Spec

FASTER,and
at a LOWER COST
than our competition.
VARIATION is the enemy!
Air
Academy
Associates
Copyright
2005

"Always know the language of the enemy."
2

Graphical Meaning of a Distribution

y (measure of performance)

130

140

150

160

170

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Academy
Associates
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2005

3

Graphical Meaning of y

y (measure of performance)

130

140

160

150
y170

153

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Academy
Associates
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2005

4

Graphical Meaning of Points of Inflection

Point of Inflection

Point of Inflection

y (measure of performance)

130

140

160

150
y

170

153

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Academy
Associates
Copyright
2005

5

Graphical Meaning of
= distance from the center of the distribution to a point of inflection

Point ofInflection

For this example,
7 = 160 - 153

y (measure of performance)

130

140

160

150
y

170

153

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Academy
Associates
Copyright
2005

6

Graphical View of Variation and
Six Sigma Performance
The Sigma Capability of a process performance measure compares the Voice of the
Process with the Voice of the Customer, and it is defined as follows:
The number of Sigmasbetween the center of a process performance measure distribution
and the nearest specification limit
Lower
Specification
Limit

3 Process

Upper
Specification
Limit

Determined by
the customer
-6

-5

-4

WASTE

-3

-2

0

-1

+1

+2

+3

-6 -5 -4 -3 -2

-1

+5

WASTE

6 Process

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+4

3 Process Centered
•Process is WIDER
than the
specifications,
causing waste and
Determined by cost of poor quality
the customer

0 +1

+6
6 Process Centered
• Process FITS well
within the
specifications, so
even if the process
shifts, the values fall
well within
tolerances

+2 +3 +4 +5 +6

7

Food for Thought...

The systems and products that
deliver value to our customers are
perfectlydesigned to achieve the
results we are getting today.

Air
Academy
Associates
Copyright
2005

8

DFSS – What is it?

Design For Six Sigma is:
• A methodology for designing new products and/or
processes.
• A methodology for re-designing existing products
and/or processes.
• A way to implement the Six Sigma methodology as
early in the product or service life cycle as possible.
• A wayto exceed customer expectations.
• A way to gain market share.
• A strategy toward extraordinary ROI.
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Academy
Associates
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2005

9

Why DFSS

Relative Cost to Make
a Design Change

"Classic" Six Sigma
focuses here
1000

100

DFSS focuses here

10

1

Research

Design

Development

Production

Product Stage

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Academy
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Copyright2005

• "Design in" quality when costs are lowest
• "Design in" quality when costs are lowest
• Show customers “Six Sigma” products right from the start
• Show customers “Six Sigma” products right from the start
10

The Opportunity of DFSS
Resources
Required

Revenue
Generated

DFSS Vision:
Predictive Design
Revenue
w/ DFSS

Revenue
w/o DFSS

Launch Launch

Air
Academy...
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