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Course fee and EPTO/APTO units differ for on-site training.Design for Six Sigma: New Product Development
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Duration: 10.0 days CEUs: 6 | ||
| (This course is not currently scheduled.) |
This outline is provisional and subject to change.
This course introduces a complete set of ideas, methods, and tools for introducing products to the marketplace that are more likely to delight the customer and provide the desired features and functions, clearly defined customers and markets, fewer defects, the right price, and the correct availability.
Learn how to
- develop a project charter and define high-level customer benefits and needs
- define and validate a measurement system
- analyze product/service design alternatives
- develop detailed product/service/process designs
- validate product and system reliability.
Who should attend
Individuals in research, development, design, manufacturing, and marketing who routinely develop new products to meet customer needs
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Course Contents
Define
- introduction to design for Six Sigma
- project selection, which includes candidate project brainstorming and selection matrix, and determining the champion, black belt, or green belt
- idea generation, customer and business needs
- develop a project charter, which includes define the problem and business need, development objective, scope and limitations, key deliverables, goals and completion date, and financial ROI analysis
- identify target customers and stakeholders which includes target customers, stakeholder analysis, and team members
- define customer benefits and needs (high level)
- market research and analysis, which includes market level competitive analysis, develop the business case, preliminary VOC and CTQs, preliminary development requirement specification and WBS
- determine business and market risks, which includes project risk assessment
- define key product development milestones and plan, which includes project plan and timeline and project lead
- define development success metrics
- capture and summarize the voice of the customer (VOC, detailed, which includes surveys, data collection plan, and summarize all VOC findings
- define product/service critical to quality (CTQs), which includes CTQ tree and determine CTQ risks
- QFD house of quality, which includes customer needs to functional performance requirements and detailed product requirements specification
- competitive benchmarking
- foundation statistics, which include basic statistics and distribution analysis
- design and validate measurement system, which includes Gage R&R, linearity, bias, measurement validation, and attribute MSA
- update ROI, detailed project plan and timeline
- analyze product/service design alternatives, which include design for X, the role of design and process constraints, brainstorm design alternatives, creative problem solving, TRIZ, and summarize system design concepts and alternatives
- select concept design, which includes design performance and solution alternative evaluation, solution evaluation matrix, concept design for manufacturability (DFM) and lean evaluation, functional requirements to design QFD, house of quality number two, system level FMEA, and select concept design and verify it meets all CTQs
- define process, material and part requirements, which includes define part or raw materials requirements and QFD HOQ2a design to process, part or raw materials flow down
- design of experiments for robust parameter design, which includes DOE core concepts, pre-DOE, full factorial and catalogue designs, custom designs, mixture designs, and tolerance design and DOE
- assess design risks using FMEA
- update project pl
- develop detailed product/service/process designs
- complete detailed product parameter design
- product to process QFD
- process recipe generation and optimization
- product and process tolerance design and analysis
- visualization of the tolerance problem and customer requirements
- use of DOE and the transfer function in tolerance design
- role of data and the distribution of X in tolerance analysis
- worst case tolerance design
- RSS tolerance design
- defining guard bands for manufacturing and test applications
- detailed design for manufacturability
- DFM twelve principles
- DFM statistics, scorecard and redesign options
- DFM scorecard
- product characterization and test planning
- define all product characterization and test plans
- sample size determination
- develop manufacturing plans, documentation and marketing collateral
- develop all marketing collateral
- process mapping, workflow, simula
- validate product and system reliability
- verify design meets all customer CTQs and requirements
- verify the product meets cost and availability requirements
- validate design performance, yield and process capability
- sample size
- define process controls
- design closed loop process controls and SPC
- process FMEA
- develop control plan
- error proofing and system checks
- final financial ROI and project performance summary
- lessons learned and close the project
Course Materials
Students receive a hardcopy of the course notes and, in some courses, can choose to take home a copy of the course data.
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Not currently scheduled. Available for on-site training or can be scheduled at any SAS training facility if demand warrants.
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