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DFSS, Innovation and I-TRIZ Tools “Innovative Designs for Six Sigma”. BREAKTHROUGH IMPROVEMENT AND INNOVATIVE DESIGN ORIGINS. Global Leaders in their fields. Dr. Joseph M. Juran Father of Breakthrough Improvement. Genrich Saulovich Altshuller Father of TRIZ.

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slide1

DFSS, Innovation and I-TRIZ Tools

“Innovative Designs for Six Sigma”

breakthrough improvement and innovative design origins
BREAKTHROUGH IMPROVEMENT AND INNOVATIVE DESIGN ORIGINS

Global Leaders in their fields

Dr. Joseph M. Juran

Father of Breakthrough

Improvement

Genrich Saulovich AltshullerFather of TRIZ

our credibility and experience
OUR CREDIBILITY AND EXPERIENCE
  • A 23-year successful Juran track record in achieving bottom-line resultsthrough 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 Institutestaff 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 international inc
IDEATION INTERNATIONAL INC.
  • Ideation established 1992
  • Merged with Kishinev School (Leading TRIZ School in Russia)
  • Headquarters in Southfield, MI
  • 85% of the world’s leading TRIZ Scientists
  • Installed customer base of over 2,000 enterprises worldwide
  • Active in 40 countries and 65 universities plus numerous partnerships, strategic alliances and resellers established worldwide
ideation s mission
IDEATION’S MISSION

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.

what is ideation s business
WHAT IS IDEATION’S BUSINESS?

Provider of I-TRIZ:

Education

Software

Publications

Analytical

Services

Age of Application

Inventive Problem Solving

Books

Papers

54 yrs

Failure

Analysis

22 yrs

Anticipatory

Failure

Determination

Book

Papers

Failure

Prediction

22 yrs

Directed

Evolution

Under

Development

Papers

12 yrs

juran institute s mission

Our mission is to provide

professional consulting services to

improve continuously the performance of our clients’ processes, products, people, and profits.

JURAN INSTITUTE’S MISSION
juran institute
JURAN INSTITUTE
  • Founded 22 years ago by Dr. J. M. Juran.
  • Leading source world-wide for research, consulting, and education in managing for Six Sigma quality to achieve superior business results.
  • Six Sigma Quality is one of our key businesses today. In the present and future, like the past, we have built on our competencies - like our competitors. One difference, the Juran Quality Model is the heart of Six Sigma.
  • High quality (high sigma values) reduces costs, increases revenues, creates loyal customers and a great culture.
  • Not all Six Sigma providers are alike. Juran Institute tries to adapt and be flexible in meeting local site requirements, as well as corporate goals.
what are juran institute s services and products
WHAT ARE JURAN INSTITUTE’S SERVICES AND PRODUCTS?

Provider of Breakthrough

Training

E-learning

Publications

Consulting

Services

Licensing

Breakthrough Problem Solving

Books

Papers

Design for

Six Sigma

Books

Papers

Under

Development

DMAIC Six Sigma

N/A

Strategic Deployment

Under

Development

Papers

i design for six sigma defined
I- DESIGN FOR SIX SIGMA…DEFINED
  • I-DFSS –
    • The Concurrent Development and Introduction of a new or radically redesigned product or service and all of the processes (Design, Procurement, Production, Logistics and Distribution, Service and Sales) that enable the product or service to achieve Six Sigma business performance.
    • A Phased Methodology which includes both the design tools and innovative I-TRIZ tools for designing products (goods, information or services) and processes that generate customer value.
      • The phases are Define, Measure, Analyze, Design, Verify
innovative designs for six sigma defined
INNOVATIVE DESIGNS FOR SIX SIGMA…DEFINED

I-DFSS:

New Product/Service Introduction to Achieve Six Sigma Business Performance

MARKET

RESEARCH

DESIGN

PRODUCTION

LOGISTICS

DISTRIBUTION

SERVICE

DMADV

SALES

CUSTOMERS

what is design for six sigma dfss
WHAT IS DESIGN FOR SIX SIGMA (DFSS)?

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.

the dmadv methodology and tools

Define

Measure

Analyze

Design

Verify

TeamCharter

Pilot

DetailedDesign

CTQs

High-levelDesign

THE DMADVMETHODOLOGY AND TOOLS

DESIGN FOR SIX SIGMA

Initiate, scope,and plan theproject

Under-standcustomerneeds andspecifyCTQs

Developdesignconceptsand high-level design

Developdetaileddesign andcontrol/testplan

Testdesign andimplementfull-scaleprocesses

DELIVERABLES

TOOLS

Mgmt Leadership  Customer Research  FMEA/Errorproofing

Project QFD Process Simulation

Management Benchmarking Design Scorecards

some of our clients
SOME OF OUR CLIENTS...

Commercial Electronics

South Korea based company-wide implementation of Six Sigma, including South Korea, Hungary, India, Indonesia, Malaysia, Mexico, Spain, United Kingdom and United States.

some of our clients15
SOME OF OUR CLIENTS...

Satellite Manufacturer

Implemented Design for Six Sigma

ideation s successes to date automotive industry
IDEATION’S SUCCESSES-TO-DATE:AUTOMOTIVE INDUSTRY
  • Dana Corporation
  • Rockwell Int’l Automotive
  • TRW Automotive
  • ITT Automotive
  • Jaguar
  • GM
  • Ford
  • Toyota
  • Chrysler
  • Eaton

Cost reduction, warrantees, recalls, new design, patent circumvention, failure analysis, failure prediction, training

  • Break squeal
  • Brake roughness
  • Noise and vibration
  • Transmission
  • Air bag
  • Electrostatic paint
  • Tail light
  • Seat cover
  • Wind tunnel
  • Plastic fuel tank
ideation s successes to date chemical industry
IDEATION’S SUCCESSES-TO-DATE:CHEMICAL INDUSTRY
  • Conoco
  • Solutia
  • Rohm & Haas
  • Dow
  • Amoco
  • Dupont

Cost reduction, breakthrough/discovery, manufacturing processes, safety, quality, reliability, failure analysis

  • Plastics
  • Chemical processing
  • Catalysts
  • Reactor
  • Aromatic oxidation
  • Distillation/separation
  • New material development/design
ideation s successes to date oil industry
IDEATION’S SUCCESSES-TO-DATE:OIL INDUSTRY
  • Amoco
  • Shell
  • Exxon
  • Mobil

Cost reduction, reliability, failure analysis, new design, training

  • Exploration
  • Method of discovery
  • Refineries
  • Post processing
    • Gas
    • Fuel oil
  • Enhanced oil recovery
  • Dual grading drilling
  • Expandable casing
  • Hydro carbon processing
    • on shore
    • off shore
  • Transportation
ideation s successes to date medical industry
IDEATION’S SUCCESSES-TO-DATE:MEDICAL INDUSTRY
  • Bristol Myers
  • Zeneca (UK)
  • Johnson & Johnson
  • Cardiovascular
  • Roche

New design, patent circumvention, cost reduction, failure prediction, training

  • Medical instrumentation
  • Sanitary products
  • Blister packaging of pills
ideation s successes to date electronics electrical industry
IDEATION’S SUCCESSES-TO-DATE:ELECTRONICS/ELECTRICAL INDUSTRY
  • Northern Telecon (Canada)
  • Solarex
  • Helix
  • Toshiba
  • Sony
  • LG Electronics
  • Honeywell
  • Motorola
  • Philips Electronics
  • Hitachi
  • ITT
  • Arteche (Spain)
  • Visteon

Cost reduction, new technologies, reliability, manufacturing processes, training

  • Cell phones
  • Microchips
  • PC boards
  • Radio
  • Headset
  • High voltage transformers
  • Power supplies
  • Navigation systems
ideation s successes to date aviation industry
IDEATION’S SUCCESSES-TO-DATE:AVIATION INDUSTRY
  • Rolls Royce
  • McDonnel Douglas Aerospace
  • NASA
  • Hughes Aircraft
  • TRW
  • BF Goodrich
  • Litton
  • Boeing
  • Pratt & Whitney
  • Techspace Aero (Belgium)
  • Honeywell
  • Allied Signal
  • Rockwell International

Cost reduction, safety, reliability, quality, new design, failure analysis and prediction, training

  • C-17
  • F-22
  • Engines
  • Valves
  • Containment ring
i dfss design project

New

Processes

New

Processes

I-DFSS DESIGN PROJECT

CASE 1

CASE 2

CASE 3

No Current Product or Process

DPMO

COPQ

DPMO

COPQ

CurrentProduct

CurrentProduct

NewProduct

But:

CTQ’s

Current

Processes

High-level Design

Design

Design

CTQ GAP“Base LinePerformance”

Manufacturing

Cp, Cpk

COPQ

Distribution

DesignScorecard

Service

Marketing

REDESIGN

NEW PROCESS DESIGN

NEW PRODUCT AND

PROCESS DESIGN

Base Line Performance OK

Product Base Line Performance OK(May be of little value)

No Base Line Performance

slide23

SCIENTIFICALLY BASED APPLICATIONS: SYSTEMATIC, STRUCTURED INNOVATION

Strategically Evolving Future Generations of Technologies & Systems

Directed Evolution

DE

Inventive

Problem

Solving

Anticipatory

Failure

Determination

AFD

IPS

Surgical Removal of Tough Technological Problems

Failure

Analysis

Failure

Prediction

Elimination of Contradictions

Invention of Failure Modes

i design for six sigma
I- DESIGN FOR SIX SIGMA
  • Pre-DEFINE Phase
    • INTRODUCTION TO SIX SIGMA
    • HOW TO THINK ABOUT DFSS/NEW PRODUCT INTRODUCTION (NPI)
    • I-TRIZ/Directed Evolution (DE)
      • Strategic vision
      • Logical chain of product concepts
      • Product evolution roadmap
i design for six sigma25
I- DESIGN FOR SIX SIGMA
  • DEFINE Phase
    • INTRODUCTION TO DEFINE
    • ESTABLISH DESIGN PROJECT
    • FINANCIAL ANALYSIS
    • PROJECT MANAGEMENT AND RISK ASSESSMENT
    • SUMMARY; ISSUES TO CONSIDER
i design for six sigma26
I- DESIGN FOR SIX SIGMA
  • MEASURE Phase
    • INTRODUCTION TO MEASURE
    • ESTABLISH CTQ’s AND CTI’s
    • I-TRIZ/Innovation Situation Questionnaire & Problem Formulator
      • Design problem documentation
      • Design expectations
    • INTRODUCTION TO PROBABILITY, STATISTICS AND PREDICTION
    • MSA (Variables, Attribute and Data quality)
    • PROCESS CAPABILITY (Variables and Attribute)
    • RISK ASSESSMENT
    • I-TRIZ/Anticipatory Failure Determination (AFD)
      • Failure prediction
    • DESIGN SCORECARD
i design for six sigma27
I- DESIGN FOR SIX SIGMA
  • ANALYZE/HIGH-LEVEL DESIGN Phase
    • INTRODUCTION TO HIGH-LEVEL DESIGN
    • DEVELOP DESIGN ALTERNATIVES
    • I-TRIZ/Innovative Problem Solving (IPS)
      • Description of design options (alternatives)
      • Analysis of design alternatives for technological barriers and contradictions
    • DEVELOP HIGH-LEVEL DESIGN (VA/VE)
    • MULTI-VARI ANALYSIS
    • CONFIDENCE INTERVALS AND SAMPLING
    • HYPOTHESIS TESTING AND ANOVA
    • EVALUATE HIGH-LEVEL DESIGN
    • I-TRIZ/Anticipatory Failure Determination (AFD)
      • Failure analysis and prediction
i design for six sigma28
I- DESIGN FOR SIX SIGMA
  • DETAIL DESIGN Phase
    • INTRODUCTION TO DESIGN
    • RISK ASSESSMENT/FALURE ANALYSIS
    • I-TRIZ/Anticipatory Failure Determination (AFD)
      • Failure analysis
    • TAGUCHI METHODS AND ROBUST DESIGN
    • TOLERANCING
    • DOE with RSM
i design for six sigma29
I- DESIGN FOR SIX SIGMA
  • DETAIL DESIGN Phase (cont’d)
    • RELIABILITY and AVAILABILITY
    • NON-PARAMETRIC STATISTICS
    • SIMULATION with Monte Carlo Methods
    • DESIGN FOR MANUFACTURABILITY/DESIGN FOR ASSEMBLY
    • DVT/TESTABILITY
    • DESIGN SCORECARD
i design for six sigma30
I- DESIGN FOR SIX SIGMA
  • DETAIL DESIGN Phase -- CUSTOM FEATURES
    • THE TOOLS OF DETAIL DESIGN
    • CONCURRENT ENGINEERING
    • SOFTWARE ENGINEERING METHODS AND TOOLS

(CMM, CASE)

ENHANCED DESIGN FOR:

  • Commercial/Competitive Success
  • Manufacturability
  • Serviceability
  • Reliability
  • Availability
  • Information Management
  • Control
i design for six sigma31
I- DESIGN FOR SIX SIGMA
  • VERIFY Phase
    • INTRODUCTION TO VERIFY
    • DESIGN FOR CONTROL
    • DESIGN FOR MISTAKE- AND FOOLPROOFING
    • STATISTICAL PROCESS CONTROL (SPC)
    • MVT
    • TRANSITION TO PROCESS OWNERS
    • I-TRIZ/Directed Evolution (DE)
      • Logical sequence of new scenarios
      • Strategic knowledge base and patent portfolio
      • Targeted competitive intelligence
      • New product evolutionary stages
    • SUMMARY; ISSUES TO CONSIDER; PROJECT CLOSURE
i design for six sigma32
I- DESIGN FOR SIX SIGMA
  • VERIFY Phase -- CUSTOM FEATURES
      • PILOT TESTING
      • FULL-SIZE SCALE-UP AND COMMERCIALIZATION
      • DESIGN INFORMATION AND DATA MANAGEMENT
      • LEAN MANUFACTURING
i design for six sigma33
I- DESIGN FOR SIX SIGMA

 DMADV Training/Project Map

IDEAL

15 - 16 Weeks

Training

Weeks

Project

D-M

A

D

V

1 3 1 4 1 4 - 6 1 4 - 6

D-M

PP

A

DR-2

D

DR-3

V

DR-4

DVT

MVT

19 - 22 Weeks

(5-6 Months)

  • Critical Success Factors:
  • Project starts with training
  • Project < 6 months
  • Project phases match training schedule
i design for six sigma34

Product Planning Project

Project

I- DESIGN FOR SIX SIGMA

 DMADV Training/Project Map

REAL

(A)

?

Training

Project

Mass Production

Start

DR-2

OK

(B)

D-M

Training

Start

Consulting

(C)

?

Training

Start

DR-3

No

(D)

Training

Project

Gap

Start

six sigma dmadv training flow

Define/Measure

D/M

Analyze

A

Design

D

Verify

V

Certification

Project

Statistics, Finance

Leadership Skills

SIX SIGMA DMADV TRAINING FLOW

JURANSr. Instructor

Executive Briefing

4-8 hrs

Preparations

JURANSr. Instructor

Champion Training/Workshop

2 days

DMADV

Go-No go Decision

Black Belt Training

Black Belt Project

JURANINSTRUCTOR(first wave)

Total Duration:

4-6 months

Trained Black Belt

CertifiedBlack Belt

No

?

Yes

Master Black Belt Program

JURANSr. INSTRUCTOR

Total Duration:

4-6 months

Master BlackBelt Project

Certified MBBs