Design for Lean Six Sigma Book

Preface     xv
Acknowledgments     xix
Introduction     1
The Goal     1
Design for Six Sigma - State of the Art     2
Approach     3
Guide to This Book     7
Driving Growth through Innovation     11
Delivering on the Promise     11
Creating a Better Promise     12
Ambidextrous Organization     14
Platforms for Growth     17
Innovation and Design     18
Managing the Paradox of Preservation and Evolution     20
Types of Paradoxes     21
Conclusions     28
Process for Systematic Innovation     29
Balanced Innovation Portfolio     30
Effective Teams for Collaboration     32
Process for Executing Innovation Projects     35
Proven Techniques and Tools     38
Climate for Innovation     39
The Governance System     40
Lean Six Sigma Essentials     41
Origins of Six Sigma     42
Six Sigma Approach     43
Origins of Lean     47
Lean Six Sigma: Faster, Better, and Cheaper     55
Deploying Design for Lean Six Sigma     59
Deploying DFLSS     59
Design for Lean Six Sigma Enterprise     66
Executive Sponsors     67
Deployment Champions     68
Design Project Champions     68
Design Black Belts     68
Core Team     68
Extended Team     69
Building Support Infrastructure     69
Capturing the Voice of the Customer     73
Defining Elements of Customer-Producer Relationship     75
Customer Expectations     78
Methods of Collecting Customer Expectations     83
Research Ethics     89
Design Axioms and Their Usefulness in DFLSS     91
Design Axioms     92
Domain Thinking     93
Designing of MTS Software System     96
Designing a System that Will Market Sporting Goods     101
Designing a Fan Belt/Pulley System     104
Use of Design Principles in an Academic Department     106
Mechanical Engineering Department at MIT     106
FR-DP Identification     108
Actions Taken     109
Designing a University System that Will Teach Students Only through the Internet     112
Implementing Lean Design      115
Key Principles of Lean Design     115
Strategies for Maximizing Value and Minimizing Costs and Harm     118
Modular Designs     118
Value Engineering     122
The 3P (Production, Preparation, Process) Approach     123
Theory of Inventive Problem Solving (TRIZ)     127
Introduction to TRIZ     127
TRIZ Journey     129
TRIZ Road Map     129
Ideality Equation     131
Itself Method     132
TRIZ Analysis Tools     132
TRIZ Database Tools     139
Case Examples of TRIZ     147
Improving the Process of Fluorination     147
Coordinate Measuring Machine (CMM) Support Problem     152
Robustness through Inventions     157
What Is a Robustness Invention?     159
Research Methodology     160
Results of the Patent Search     161
Robust Invention Classification Scheme     161
Signal-based-Robust Invention     163
Response-based Robust Invention     165
Noise-factor-based Robust Invention     167
Control-factor-based Robust Invention     169
Design for Robustness     171
Engineered Quality      171
Evaluation of the Function Using Energy Transformation     173
Studying the Interactions between Control and Noise Factors     174
Use of Orthogonal Arrays (OAs) and Signal-to-Noise Ratios to Improve Robustness     174
Two-step Optimization     174
Tolerance Design Using Quality Loss Function     174
Additional Topics in Designing for Robustness     175
Parameter Diagram (P-diagram)     175
Design of Experiments     176
Signal-to-Noise (S/N) Ratios     178
Role of Simulations in Design for Robustness     179
Example - Circuit Stability Design     180
Control Factors and Noise Factors     181
Parameter Design     182
PCB Drilled-hole Quality Improvement     184
Introduction     185
Drilled-hole Quality Characteristics     186
Background     186
Hole-quality Standard     187
Experiment Description     190
Selection of Levels for These Factors     191
Designing the Experiment     192
Predictions and Confirmation Run     195
Benefits     196
Design of a Valveless Micropump Using Taguchi Methods      197
Introduction     197
Working Principle and Finite Element Modeling     199
Design for Robustness     200
Conclusions     208
Robust System Testing     209
Introduction     209
A Typical System Used in Testing     210
Role of the Orthogonal Arrays     211
Method of Software Testing     212
Study of Two-factor Combinations     213
Construction of Combination Tables     213
MTS Software Testing (Case Study 1)     215
Case Study 2     219
Analysis of Results     221
Debugging the Software     221
Conclusions     223
Development of Multivariate Measurement System Using the Mahalanobis-Taguchi Strategy     225
What Is Mahalanobis-Taguchi Strategy?     226
Stages in MTS     229
Signal-to-Noise Ratio - A Measure of Prediction Accuracy     231
Types of S/N Ratios in MTS     232
Medical Case Study     234
Stage 1: Development of Measurement Scale Using Mahalanobis Space     234
Stage 2: Validation of the Measurement Scale     235
Stage 3: Identification of Useful Variables (Development Stage)     236
Case Example 2: Auto Marketing Case Study     240
Introduction     240
Construction of Mahalanobis Space     241
Validation of the Measurement Scale     241
Identification of Useful Variables     242
Case Study 3: Improving Client Experience     245
Methodology     245
Improvements Made Based on Recommendations from MTS Analysis     246
Improvement of the Utility Rate of Nitrogen while Brewing Soy Sauce     247
Introduction     247
Process of Producing Soy Sauce or Tamari     248
Selection of Factors for MTS Application     248
MTS for Aging     249
MTS for Koji-molding     249
Application of MTS for Measuring Oil in Water Emulsion     250
Introduction     250
Application of MTS     251
Prediction of Fasting Plasma Glucose (FPG) from Repetitive Annual Health Check-up Data     252
Introduction     252
Diabetes Mellitus     253
Application of MTS     253
References     255
Appendixes     263
TRIZ Contradiction Matrix     265
40 TRIZ Inventive Principles     267
Some Useful Orthogonal Arrays      269
Equations for Signal-to-noise (S/N) Ratios     277
Related Topics of Matrix Theory     281
Index     287