Design for Six Sigma (DFSS) is a proactive approach to product design that aims to prevent quality problems, while traditional Six Sigma is a reactive approach focused on improving existing processes. DFSS uses tools like Quality Function Deployment and Failure Mode and Effects Analysis during the design process to translate customer needs into engineering requirements and optimize designs to achieve high quality levels. Key challenges to implementing DFSS include overcoming cultural resistance to change and adapting new technical methods and tools. Leadership support is critical to making DFSS successful through clear communication of the quality vision and goals.

1. Six Sigma vs. Design for Six Sigma (DFSS) Dr. Suresh C. Rama Senior Manager, Quality Systems Global Engine Manufacturing Alliance (GEMA) Dundee, MI

3. What are these companies have in common? PROFITABILITY QUALITY CUSTOMER LOYALTY INNOVATION

8. Quality as a Strategy

11. Benefits of 6 Sigma • Generic Sigma Level Defects Per Million Cost % of Sales * 3 66,807 25 - 40% 4 6,210 15 - 25% 5 233 5 - 15% 6 3.4 < 1% Savings (3 to 4.7 Sigma): $250K per project Benefits (4.7 to 6 Sigma): Greater market share • Savings Realized ** – GE: $750M (‘98), $1.5B (‘99) – Motorola: $800-$900M / year ($15B over 11 years) – ABB: $900M / year – Allied Signal: $500M (‘98), $600M (‘99) * Waste due to additional inspection, tests, rework, scrap, customer dissatisfaction, etc. ** Quoted savings from the book “Six Sigma” by Mikel Harry & Richard Schroeder; Allied Signal quote from Industry Week

15. The “5 Sigma Wall” Break through the “5  wall” by redesign for manufacturability Process Improvements Plus Product Redesign to Match Improved Process Capability Time Sigma Level 6 5 4 3 Redesign Benefit Process Improvements Only “ 5  Wall”

17. 6 Sigma vs. Design for Six Sigma Traditional 6-Sigma - Reactive Design for Six Sigma - Proactive Minimize sensitivity to variation by choosing good nominal values for Xs Minimize variation (sigma) by process capability improvement

20. DFSS Process D. F. S. S. Customer Happy Optimize Design Optimize Quality, Reliability and Durability and improve Robustness Verify & Validate Verify predicted Quality and Reliability Develop Concepts Develop, select and synthesize concepts for better designs Identify Opportunity Select Projects based on Quality indicators and gap to targets Define Requirements Translate Voice of the Customer to Design Requirements

26. Remember? What are these companies have in common? All of them use Design for Six Sigma - effectively

28. THANK YOU! Questions?