Academic literature on the topic 'Design for Six Sigma'

The literature suggests that organisations which have adopted Six Sigma have realised that upon achieving a Five Sigma level the only way to surpass this is to redesign the process(es) by means of Design for Six Sigma (DFSS). For others, the selection of Six Sigma over the DFSS approach is not a definitive question and just a guideline can be provided. A major objective of this research was to extend the selection of the requisite Six Sigma approach beyond the sigma level case and the general guidelines, towards a multi-criteria decision using established techniques. Thus, two research questions were defined: what influences the selection of the requisite Six Sigma approach, i. e. Six Sigma versus DFSS? and, how effective is the use of Multi-Criteria Decision Analysis (MCDA) techniques in the selection of the requisite Six Sigma approach? An action research methodology was applied where one Six Sigma project, one DFSS project and one Six Sigma project applied in a non-manufacturing process were implemented and analysed in collaboration with 3M Corporation, General Domestic Appliances (GDA) and Land Rover. From the action research spiral it was concluded that the sigma level has a positive association with the selection of redesign or improvement efforts within Six Sigma, however the Five Sigma level cannot necessarily dictate the use of one approach over the other. Besides the sigma level the selection of the requisite Six Sigma approach is influenced by multiple and conflicting criteria. In addition, the selection can occur at different stages of the methodologies. To assist decision-makers in organising, synthesising and optimising the criteria affecting this decision, the Stochastic Analytic Hierarchy Process (SAHP) was developed and applied to the problem at hand. The SAHP was developed on the basis of Analytic Hierarchy Process (AHP) and disparate sources of relevant literature. SAHP provides a mechanism for achieving a more effective selection of the requisite Six Sigma approach in the form of considering multiple and conflicting criteria using quantitative and qualitative information under uncertainty. In contrast to the traditional AHP, SAHP incorporates probabilistic distributions to incorporate uncertainty that people have in converging into a Likert scale their judgments of preferences. The vector of priorities is calculated using Monte Carlo simulation and the final rankings analysed for rank reversal using statistical analysis with managerial aspects introduced systematically. The concept and implementation of SAHP is new to the selection of the requisite Six Sigma approach and as such it constitutes the main innovation to result from this research. It extends the selection of the requisite Six Sigma approach towards a systematic multi-criteria decision considering multiple and conflicting criteria under uncertainty. Furthermore, while SAHP was originally conceived as a specific aid to the improve or redesign issue within Six Sigma, this research indicates that it is potentially much more widely applicable. This research also provides evidence of how different factors affecting the selection of requisite Six Sigma approach were considered. Further areas of research include the use of a positivist method in order to increase the sample size of the research and identify different factors affecting the decision improve or redesign. The development of SAHP software and extending the SAHP practice to different multi-criteria decisions are also potential areas for further research.

Design for Six Sigma (DFSS) is a further development of the Six Sigma draft to carry through preventing quality measures in developing and designing of new products and processes. With increasing demands on enterprises development processes to be more safety and faster the need of DFSS arise as a product, process and service development concept in the organisations. Design for Six Sigma aims to improve and structure the development process of an organisation and consider the application of the innovation problem solving. The concept aims to leave the structure of the traditional Six Sigma concept and instead, from an innovative perspective, search for new solutions to existing problems. The concept constitute of a toolbox with a lot of quality tools that are divided into phases in a development model. Combined with the organizations project model the Design for Six Sigma concept can give rise to excellent results in the work with developing and designing of new products and processes. The condition to succeed is that the draft has been established and accepted with the organizations collaborator. This thesis work summarizes the contents of the Design for Six Sigma concept. The concentration of the performance has been the underlying theory behind the DFSS draft together with the contents of the methodology and the included tools.<br>Design for Six Sigma (DFSS) är en vidareutveckling av Sex Sigma-konceptet för att genomföra förebyggande kvalitetsåtgärder vid ny- och vidareutveckling av produkter och processer. Med ökade krav på säkrare och snabbare utvecklingsprocesser hos organisationer uppkommer ett behov av detta produkt-, process- och tjänsteutvecklingskoncept. Design for Six Sigma konceptet behandlar strukturering och utveckling av en verksamhets utvecklingsprocess och handlar mycket om applicerandet av det som vanligen benämns innovativ problemlösning. Konceptet syftar således till att frångå Sex Sigmas traditionella strukturerade arbetssätt och istället, utifrån ett innovativt angreppssätt, söka fastställa helt nya lösningar på ett problem. Konceptet består av en verktygslåda med kvalitetsverktyg uppdelade i faser i en utvecklingsmodell. Kombinerat med en organisations projektledningsmodell kan Design for Six Sigma medföra goda resultat vid produkt och processutvecklingsarbete under förutsättning att förståelse och acceptans hos medarbetarna etablerats. Detta examensarbete sammanfattar innehållet i Design for Six Sigma-konceptet. Fokus har legat på DFSSs bakomvarande teorier vilka utgör grunderna till konceptet samt dess innehåll och verktygslåda.

The role of quality control is to correctly translate customers´ requirements into materialized products to achieve customers’ satisfaction. Today Product Development Process (PDP) becomes the stage to improve and to obtain successful products. In the 1980s, Six Sigma appeared as an attempt to improve some aspects of products and services in order to reduce failures in production as much as possible. But there still was a lack of customer perspective over product development project. This thesis approached the lack of customer insight with a new product development process, Design for Six Sigma (DFSS). Examples that describe how DFSS works and its implementation are still missing, therefore the purpose of this master thesis is to prove if the implementation of DFSS would be efficient, effective and closer connected to the customer of mass- production companies. DFSS is based on processes, roles and tools. However, it is questionable whether the suggested role structure and a uniformed process are able to implement in the real world. The methods used for this research project were two interviews with two mass customization companies, qualitative data collection and finally analyzing the collected data by comparing them with the theory of DFSS. This PDP ensures the track, and enhances creativity and innovation, taking the process beyond its capabilities. Moreover, the conclusions of the thesis show that there is no need for a uniformed model, making DFSS more useful and trickier for competitors. The lack of a uniformed model allows to overcome the innovative ability. The skills to reach these roles and the creation of a team within the company are more important than roles and backgrounds themselves. In spite of knowledge of expertise areas, the task is more related to control the collaboration, communication and flow of information within the group. DFSS becomes a successful solution for customer insight, a good combination of tools and techniques. But it does not mean that implementing accurately a certain methodology is the right solution.

Este presente trabalho visa avaliar a aplicação da metodologia Design for Six Sigma (DFSS) ao processo de desenvolvimento de veículos (PDV) visando atingir níveis de qualidade Seis Sigma quando do início do processo de fabricação. Na verdade, quando se fala em fabricar produtos que já nasçam com níveis de qualidade Seis Sigma, não significa que seja mandatório que se obtenha a honrosa relação de 3,4 defeitos por milhão de oportunidades, mas sim que proporcionem resultados positivos em relação à melhoria da qualidade, otimização de custos, redução do tempo de desenvolvimento, vislumbrando o mais importante de todos os aspectos: o total entusiasmo do cliente. Para tanto, quando se fala da aplicação do DFSS no âmbito do desenvolvimento de veículos, o panorama deste contexto torna-se relativamente mais amplo e complexo, face ao nível de desenvolvimento tecnológico deste setor. O assunto é introduzido descrevendo-se o processo de desenvolvimento de veículos em sua abordagem atualmente difundida, alicerçada por um processo bem definido e estruturado, para se poder introduzir o DFSS neste processo. Antes, porém, introduz-se toda a metodologia referente ao Seis Sigma, por ser o fundamento base para a criação do DFSS. Por fim, a colocação de um estudo de caso procura relatar a aplicação da metodologia DFSS aplicada especificamente para a GM, procurando relatar a estratégia da aplicação, bem como seus principais ganhos alcançados.<br>This present work aims to evaluate the application of the Design for Six Sigma (DFSS) methodology to the vehicle development process (VDP) seeking to reach Six Sigma quality levels when the beginning of the production process. Actually, when it is spoken in manufacturing products that are already born with Six Sigma quality levels, it doesn\'t mean that it is mandatory that must be obtained the honorable relationship of 3,4 defects per millions of opportunities, but that provide positive results in relation to the quality improvement, costs optimization, reduction of the development timing, glimpsing the most important of all of the aspects: the customer\'s total enthusiasm. For that, when it is spoken about the application of DFSS in the extent of the vehicles development, the scenery of this context becomes relatively wider and complex, face at the level of technological development of this section. The subject is introduced being described the vehicles development process in its approach currently spread, found by a very defined and structured process, to allow introducing DFSS in this process. Before, however, the whole methodology regarding Six Sigma is introduced, for being the foundation base for the creation of DFSS. Finally, the placement of a case study tries to demonstrate the application of the DFSS methodology applied specifically for GM, trying to report the strategy of the application, as well as their main reached benefits.

The purpose of this research was to develop a composite flooring system to be used in the equine surgical unit in the College of Veterinary Medicine at North Carolina State University. This material was developed due to an extensive need for a new flooring system that would accurately meet the needs of the customers and stakeholders involved. Research included the origin of Design for Six Sigma (DFSS), tools that differentiated it from previous design processes, past/present flooring solutions, structure/dynamics of a horse, horse tendencies, and composite theories. By implementing the five step procedure of DFSS, Define, Measure, Analyze, Design, and Verify, a sound product was able to be realized. Certain DFSS tools were implemented such as Voice of the Customer Analysis, Reverse Engineering, Brainstorming, Design of Experiment, Pugh Concept Analysis, Computer Aided Design, and Finite Element Modeling. The end solution was a composite flooring system that meets the needs of not only the primary market but many secondary markets as well.

Submitted by RAQUEL TEIXEIRA CAMPOS null (kel_76@hotmail.com) on 2017-07-07T00:11:20Z No. of bitstreams: 1 Dissertação final DFSS_Raquel Campos.pdf: 1845537 bytes, checksum: d48eed6005c37ea47313bb9a9f74b44e (MD5)<br>Approved for entry into archive by LUIZA DE MENEZES ROMANETTO (luizamenezes@reitoria.unesp.br) on 2017-07-07T14:28:54Z (GMT) No. of bitstreams: 1 campos_rt_me_bauru.pdf: 1845537 bytes, checksum: d48eed6005c37ea47313bb9a9f74b44e (MD5)<br>Made available in DSpace on 2017-07-07T14:28:54Z (GMT). No. of bitstreams: 1 campos_rt_me_bauru.pdf: 1845537 bytes, checksum: d48eed6005c37ea47313bb9a9f74b44e (MD5) Previous issue date: 2017-06-20<br>O design for six sigma (DFSS) é um método normalmente adotado para se planejar o design do produto com alto nível de qualidade, o DFSS tem início na concepção do produto ou processo, para que os mesmos sejam projetados ou planejados isentos de erros, sem a necessidade de melhorá-los nas etapas subsequentes do processo de desenvolvimento de produtos (PDP). O objetivo deste trabalho consiste em propor um framework para a aplicação e implementação do DFSS no PDP. O método de pesquisa adotado foi dividido em duas etapas. Primeiramente foi feita uma revisão bibliográfica sistemática, posteriormente o framework teórico foi desenvolvido, e posteriormente analisado em uma empresa de grande porte e que adota o método DFSS há mais de três anos. As principais características deste framework desenvolvido e analisado são: a síntese de métodos e ferramentas específicas para a aplicação e implementação do DFSS no PDP, seguindo o passo a passo do modelo DMADV do DFSS com a descrição dos principais objetivos de cada fase do método. Os resultados da pesquisa mostraram que a utilização do DFSS encontra algumas barreiras, e que nem todas as ferramentas que o método propõe, baseadas na literatura, são utilizadas em organizações por serem ferramentas complexas. Ao final, o trabalho apresenta um novo framework baseado na análise da organização com as ferramentas e métodos aplicados por ela.<br>Design for Six Sigma (DFSS) is a commonly adopted method for designing a product with a high level of quality, starting with the design of the product or process, so that it is designed or planned without error, without the need of improvement in subsequent stages of the product development process (PDP). The objective of this work is to suggest a framework for the application and implementation of DFSS in PDP. The research method adopted was divided into two stages. First, a systematic bibliographic review was done and afterwards, the theoretical framework developed was evaluated in a large company that uses the DFSS method for more than three years. The main characteristics of this framework developed and evaluated are: the synthesis of specific methods and tools for the application and implementation of the DFSS in the PDP, following the step by step of the DMADV model of the DFSS with the description of the main objectives of each phase of the method. The results of the research presented that the use of the DFSS finds some barriers, and verified that not all tools of the method are used in organizations because they are too complex. The work presents a new framework based on the analysis of the organization with the tools and methods applied by this company.

Orientador: Daniel Jugend<br>Banca: Renato de Campos<br>Banca: Carla Cristina Amodio Estorilio<br>Resumo: O design for six sigma (DFSS) é um método normalmente adotado para se planejar o design do produto com alto nível de qualidade, o DFSS tem início na concepção do produto ou processo, para que os mesmos sejam projetados ou planejados isentos de erros, sem a necessidade de melhorá-los nas etapas subsequentes do processo de desenvolvimento de produtos (PDP). O objetivo deste trabalho consiste em propor um framework para a aplicação e implementação do DFSS no PDP. O método de pesquisa adotado foi dividido em duas etapas. Primeiramente foi feita uma revisão bibliográfica sistemática, posteriormente o framework teórico foi desenvolvido, e posteriormente analisado em uma empresa de grande porte e que adota o método DFSS há mais de três anos. As principais características deste framework desenvolvido e analisado são: a síntese de métodos e ferramentas específicas para a aplicação e implementação do DFSS no PDP, seguindo o passo a passo do modelo DMADV do DFSS com a descrição dos principais objetivos de cada fase do método. Os resultados da pesquisa mostraram que a utilização do DFSS encontra algumas barreiras, e que nem todas as ferramentas que o método propõe, baseadas na literatura, são utilizadas em organizações por serem ferramentas complexas. Ao final, o trabalho apresenta um novo framework baseado na análise da organização com as ferramentas e métodos aplicados por ela.<br>Abstract: O design for six sigma (DFSS) é um método normalmente adotado para se planejar o design do produto com alto nível de qualidade, o DFSS tem início na concepção do produto ou processo, para que os mesmos sejam projetados ou planejados isentos de erros, sem a necessidade de melhorá-los nas etapas subsequentes do processo de desenvolvimento de produtos (PDF). O objetivo deste trabalho consiste em propor um framework para a aplicação e implementação do DFSS no PDP. O método de pesquisa adotado foi dividido em duas etapas. Primeiramente foi feita uma revisão bibliográfica sistemática, posteriormente o framework teórico foi desenvolvido, e posteriormente analisado em uma empresa de grande porte e que adota o método DFSS há mais de três anos. As principais características deste framework desenvolvido e analisado são: a síntese de métodos e ferramentas específicas para a aplicação e implementação do DFSS no PDP, seguindo o passo a passo do modelo DMADV do DFSS com a descrição dos principais objetivos de cada fase do método. Os resultados da pesquisa mostraram que a utilização do DFSS encontra algumas barreiras, e que nem todas as ferramentas que o método propõe, baseadas na literatura, são utilizadas em organizações por serem ferramentas complexas. Ao final, o trabalho apresenta um novo framework baseado na análise da organização com as ferramentas e métodos aplicados por ela<br>Mestre

During the latter part of the 20th century, the service sector registered a significant growth in every developed country, as well as global competition and the pressure to offer new services to satisfy customer needs and expectations. However, whereas there has been a respectable amount of research in the service management literature, research specifically in the context of New Service Development (NSD) was very little. Linderman et al. (2003) define Design For Six Sigma (DFSS) as an organized and systematic method for the strategic improvement and for developing new products and processes using statistical tools in order to drastically reduce defects and variations perceived by the customers. Over the last decade, the general literature on Six Sigma has steadily grown. The most frequent applications have regarded the improvement of existing processes in manufacturing and services, using its well-established method, i.e. the DMAIC model, while publications on DFSS have been fewer. Furthermore, while several have been the authors that have investigated the impact of the DFSS method to product design (e.g. Chakravorty, 2009; Bañuelas and Antony, 2004; Goel and Chen, 2008), scientific research on applications of DFSS on the NSD process is very scant and there are no empirical studies on the application of the methodology to NSD. Service typologies, indeed, are heterogeneous and in literature is difficult to find methodologies to support the service design process and consequently reduce its variability. This thesis has three purposes. The first is outlining the managerial areas on which to focus the efforts and resources of the organization, in order to successfully implement the DFSS methodology to service processes. The second one is to identify a series of Best Practices for the application of DFSS to services that are transversal to every class of service process. Finally, since service processes are for characteristics, very heterogeneous, the last purpose is to formulate some models, in order to successfully adapt the methodology to different service processes and maximize the results obtained in the organization. On the basis of a first exploratory study, in order to respond to these questions, a multiple case study has been launched, comparing the results in four different organizations that have applied the Six Sigma methodology in order to design or redesign their service processes. Empirical results emerged in these case studies have been gathered and translated into forty best practices, in the form of statements, and grouped in five aspects of the methodology identified through the pilot case study above mentioned. Afterwards, we carried out a cross-case analysis to find similarities and differences between the best practices, and extrapolate the results in response to the research question, finding how the best practices fit with different classes of service process defined previously. As a final result, the data analysis allowed us to identify five models, corresponding to the five Six Sigma aspects mentioned earlier, which show how organizations should differ Six Sigma application for each kind of new service process to design or redesign. The main results of this study have been twofold. By an academic point of view, since empirical research on DFSS applications in service processes was totally lacking, this study fills an important gap in scientific literature on Six Sigma. Furthermore, important managerial implications have been developed, explaining what are the critical areas to manage to successfully apply DFSS to services and identifying both a series of general Best Practices and some specific models to better adapt the methodology to different service processes.<br>Durante l'ultima parte del 20° secolo, il settore dei servizi ha registrato una crescita significativa in tutti i paesi sviluppati, al pari della competizione globale e della necessità di offrire nuovi servizi per soddisfare bisogni e aspettative dei clienti. Tuttavia, se da un lato vi è stato un volume cospicuo di ricerca sul Service Management, gli studi sul New Service Development (NSD) sono stati di molto inferiori. Linderman et al. (2003) definiscono il Design For Six Sigma (DFSS) come un metodo organizzato e sistematico per il miglioramento strategico e per lo sviluppo di nuovi prodotti e processi tramite strumenti statistici, al fine di ridurre drasticamente i difetti e le variazioni percepite dai clienti. Nel corso dell'ultimo decennio, la letteratura generale sul Six Sigma è cresciuta costantemente. Le applicazioni più frequenti hanno riguardato il miglioramento dei processi esistenti nel settore manifatturiero e dei servizi, utilizzando il noto modello DMAIC, mentre le pubblicazioni sul DFSS hanno rappresentato una percentuale molto minore. Inoltre, mentre numerosi sono stati gli autori che hanno studiato l'impatto del DFSS alla progettazione di prodotto (e.g. Chakravorty, 2009; Bañuelas e Antony, 2004; Goel e Chen, 2008), la ricerca scientifica sulle applicazioni del DFSS al NSD è stata scarsa e non ci sono studi empirici sull‟applicazione della metodologia al NSD. Le tipologie di servizio, infatti, sono eterogenee e in letteratura è difficile trovare metodologie olistiche a supporto del processo di progettazione del servizio. Questa tesi ha tre obiettivi. Il primo è individuare quali sono le aree manageriali su cui concentrare gli sforzi e le risorse dell'organizzazione, al fine di applicare con successo la metodologia DFSS ai processi di servizio. Il secondo è quello di individuare una serie di Best Practice per l'applicazione del DFSS ai servizi, che risultino trasversali ad ogni classe di processo di servizio. Infine, poiché i processi di servizio sono per natura molto eterogenei, l‟ultimo obiettivo è quello di formulare alcuni modelli, per adattare con successo l‟applicazione della metodologia ai diversi processi di servizio e massimizzare i risultati ottenuti dall'organizzazione. Sulla base di un primo studio esplorativo, al fine di rispondere a queste domande, dei casi studio multipli sono stati avviati, confrontando i risultati in quattro diverse organizzazioni che hanno applicato il DFSS ai loro processi di servizio. I risultati empirici emersi in questi casi di studio sono stati raccolti e sintetizzati in quaranta Best Practice, in forma di asserzioni, e raggruppati nei cinque aspetti della metodologia individuati attraverso il caso studio pilota di cui sopra. Successivamente, abbiamo effettuato una cross-case analysis per trovare similitudini e differenze tra le Best Practice, ed estrapolare i risultati per rispondere alla domanda di ricerca. Come risultato finale, l'analisi dei dati ci ha permesso di individuare cinque modelli, corrispondenti ai cinque aspetti della metodologia accennati in precedenza, che mostrano come le organizzazioni dovrebbero adattare l‟applicazione del Six Sigma a seconda del tipo di processo di servizio da progettare o riprogettare. I risultati ottenuti con questo studio sono stati duplici. Da un punto di vista accademico, dal momento che la ricerca empirica sulle applicazioni del DFSS ai servizi era del tutto assente, questo studio colma una lacuna importante nella letteratura scientifica sul Six Sigma. Inoltre, importanti implicazioni manageriali sono state ottenute, spiegando quali sono le aree critiche per l‟applicazione del DFSS ai servizi e identificando sia una serie di Best Practice generali, sia alcuni modelli specifici per adattare la metodologia ai diversi processi di servizio.