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1、DFSS with SuppliersDFSS with SuppliersDFSS with SuppliersKey Message in the First Six Sigma ConventionDFSS with SuppliersKey Communications Event for SuppliersSupplier Six Sigma Convention Shangri-La Hotel August 21,2001Tower A BallroomOrange Grove Road,Singapore 258350Launched 2 Projects in the fir
2、st Six Sigma Convention:Supplier Six Sigma IntegrationDFSS with SuppliersFirst Six Sigma ConventionDFSS with Suppliers6 Sigma&Beyond6 Sigma&BeyondThe Need for“Design for Six Sigma”The 5 Sigma WallThe 5 Sigma WallDefects created by the design processDFSS with SuppliersTTV KILLER!Actual but Unplanned
3、Resource LevelPre-Release ProblemsActualTimePlanned Resource LevelPlannedTime to MarketBenefits of“Design for Six Sigma”(People,Money,Energy)Resource LevelExpected Resource Level with DFSSPredictive DevelopmentShorter Development CyclesEfficient Use of ResourcesTTV GAIN!DFSS with SuppliersDesign For
4、 Six Sigma is a common,systematic methodologywhich enables us to design products/processes that will meetor exceed the customers expectations:mRobustnessmPerformancemCost mTimeliness mVolumeThe Bottom lines of“Design for Six Sigma”DFSS with Suppliers Six Sigma BreakthroughDesign For Six Sigma“Design
5、 for Six Sigma”StrategyDFSS with SuppliersObjective of“DFSS with Suppliers”Jointly develop component design solutions and manufacturing methods,with complete characterization of margin vs specification,so as to achieve the highest possible quality with the lowest possible cost.DFSS with SuppliersIde
6、ntify Phase -Major DeliverablesIdentify supplier CTQs through Quality Function Deployment(QFD):Specific house(s)of quality to focus onGap analysis:requirement flow-down&capability flow-upDerive/obtain information and data for Scorecard assessmentDetermine Z-score of supplier processesSet supplier DP
7、U goals and formulate plans to achieve these goalsPhase Deliverables of“DFSS with Suppliers”DFSS with SuppliersDesign Phase -Major DeliverablesDetermine transfer function:DOE/RSMRevisit available informationDevelop new manufacturing technologyPropose alternative designFinite element analysisConduct
8、thorough measurement system analysis:Identify advance metrology requiredEstablish gage linearity,GR&R and correlationPhase Deliverables of“DFSS with Suppliers”DFSS with SuppliersOptimize Phase -Major DeliverablesIdentify opportunities for cost reduction:Trade-off analysisSensitivity analysisZ-scoreA
9、ssess risk of new manufacturing technology:Capability analysis,Z-scoreRisk analysisJointly finalize componentspecification:Tolerancing techniquesMonte Carlo simulationZ-scoreResponse FunctionNoYesPhase Deliverables of“DFSS with Suppliers”DFSS with SuppliersValidate Phase -Major DeliverablesReview po
10、st-treatment capability:Z-scoreDPU performance vs DPU goalsConduct reliability testing:Reliability test plans at suppliersDefine necessary long-term improvement plansDevelop control plan to maintain gain:SPC,LAT,SPAORTPhase Deliverables of“DFSS with Suppliers”DFSS with SuppliersValidate Phase -Major
11、 DeliverablesComponent qualification:First article assessmentFirst article qualification through SPQPVolume ramp approval:RRR,SSATPhase Deliverables of“DFSS with Suppliers”DFSS with SuppliersSQE DFSS Core Team2.Establishing Core and Extended TeamsMBBsCMTSix Sigma DirectorSQEsExe.Sponsors:Humberto R.
12、SQE Black BeltsSuppliersDesign CenterSuppliersSQE DirectorDFSS with SuppliersCommodity leader(Technical Advisor)Supplier DFSS GroupDC SQE Black Belt(Statistical Advisor)Master Black Belt(Statistical Advisor)Design Center SQE(Project Planning&DC Liaison)Design EngineerRegional SQE(Supplier Liaison)CM
13、TProvide supplier sourcing list Implement metrology&perform GR&RImprove&validate z scoreGuide and supervise effort in DOE/RSMLead execution of all DFSS activities at suppliersLong-term control planProvide complex statistical analysisFormulate DOESupport execution and analysisDFSS Leader within suppl
14、ier company to:Collect data and analysisQualify measuring systemDerive optimized process and transfer functionsImplement control planDocumentation of work done3.Defining Roles&Responsibilities and DFSS Workflow3.Defining Roles&Responsibilities and DFSS WorkflowQFDs from VOCJointly establish componen
15、t QFD/CTQsAssess z score criticality vs performance Prioritize CTQ&Transfer FunctionsEstablish metrologyFocal commodity person for DCChampion DFSS projectProvide leadership to FE SQEProvide info&direction in assessing scorecard&transfer function development/optimizationFA approval at optimized condi
16、tionDFSS with SuppliersJointly worked with Design Center to identify and develop all C1 CTQsDetermined Z-scores and transfer functions for part characteristics and suppliers processesZ-scores have been obtained for 99%of the CTQs,of which 69%are having Z-score 6.All measurement gaps have been addres
17、sed.GRR completed for 92%of the CTQs6.Developing Progress Tracking Matrices of DFSS Activities6.Developing Progress Tracking Matrices of DFSS ActivitiesDFSS with Suppliers2.Supplier DFSS Framework1.Major Deliverable2.Suppliers to formulate the desired DFSS framework that helps drive integration of t
18、he DFSS methodology and facilitates DFSS projects internally.DFSS with Suppliers3.Supplier DFSS Scorecard1.Major Deliverable2.SQE to develop DFSS Scorecard to both measure&appraise the Suppliers DFSS efforts.DFSS with Suppliers3.Supplier DFSS Scorecard to Recognize Best Supplier3.Supplier DFSS Score
19、card to Recognize Best SupplierSupplier DFSS Scorecard to be developed with critical input from CMT and Design Centers to promote and recognize best efforts in DFSSMore details to be worked out in the near future which may include inviting best DFSS supplier to showcase efforts in Six Sigma Achievement.DFSS with SuppliersEnd of Presentation