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
OUR CREDIBILITY AND EXPERIENCE
A 23-year successful Juran track record in achieving bottom-line results
through 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 Institute staff and
services that are unsurpassed by our competitors.
Juran Institute DFSS training and consulting materials are experiencebased, 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 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 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?
Provider of
I-TRIZ:
Education
Software
Anticipatory
Failure
Determination
Inventive Problem
Solving
Books
Papers
Failure
Analysis
Analytical
Services
Age of
Application
54 yrs
22 yrs
Book
Papers
Failure
Prediction
Directed
Evolution
Publications
22 yrs
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
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?
Provider of
Breakthrough
Training
E-learning
Breakthrough
Problem Solving
Publications
Consulting
Services
Licensing
Books
Papers
Design for
Six Sigma
Books
Papers
DMAIC Six Sigma
Under
Development
Strategic
Deployment
Under
Development
Papers
N/A
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
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)?
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
DESIGN FOR SIX SIGMA
Understand
customer
needs and
specify
CTQs
Initiate,
scope,
and plan
the
project
Define
Develop
design
concepts
and highlevel
design
Measure
Analyze
Develop
detailed
design and
control/test
plan
Design
Test
design and
implement
full-scale
processes
Verify
DELIVERABLES
Team
Charter
CTQs
High-level
Design
Detailed
Design
Pilot
TOOLS
 Mgmt Leadership
 Customer Research
 FMEA/Errorproofing
 Project
 QFD
 Process Simulation
 Benchmarking
 Design Scorecards
Management
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 CLIENTS...
Satellite Manufacturer
Implemented Design for Six Sigma
IDEATION’S SUCCESSES-TO-DATE:
AUTOMOTIVE INDUSTRY
GM
Ford
Toyota
Chrysler
Eaton
Dana Corporation
Rockwell Int’l Automotive
TRW Automotive
ITT Automotive
Jaguar
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
Dow
Amoco
Dupont
Conoco
Solutia
Rohm & Haas
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
Exxon
Mobil
Amoco
Shell
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
Johnson & Johnson
Cardiovascular
Roche
Bristol Myers
Zeneca (UK)
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
Northern Telecon (Canada)
Honeywell
Solarex
Motorola
Helix
Philips Electronics
Toshiba
Hitachi
Sony
ITT
LG Electronics
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
Boeing
Pratt & Whitney
Techspace Aero (Belgium)
Honeywell
Allied Signal
Rockwell International
Rolls Royce
McDonnel Douglas
Aerospace
NASA
Hughes Aircraft
TRW
BF Goodrich
Litton
Cost reduction, safety, reliability, quality, new design, failure analysis
and prediction, training
C-17
F-22
Engines
Valves
Containment ring
I-DFSS DESIGN PROJECT
CASE 1
CASE 2
CASE 3
No Current Product or Process

DPMO
COPQ
Current
Product

DPMO
COPQ
Current
Product
New
Product
But:
CTQ’s
Current
Processes
New
Processes
New
Processes
High-level
Design
Design

Cp, Cpk
COPQ
CTQ GAP
“Base Line
Performance”
Manufacturing
Distribution
Design
Scorecard
Service
Marketing
REDESIGN
Base Line Performance OK
NEW PROCESS DESIGN
Product Base Line Performance OK
(May be of little value)
NEW PRODUCT AND
PROCESS DESIGN
No Base Line Performance
SCIENTIFICALLY BASED APPLICATIONS:
SYSTEMATIC, STRUCTURED INNOVATION
Directed Evolution
Strategically Evolving
Future Generations of
Technologies & Systems
DE
Anticipatory
Failure
Determination AFD
Failure
Analysis
Failure
Prediction
Invention of Failure Modes
IPS
Inventive
Problem
Solving
Surgical Removal of Tough
Technological Problems
Elimination of Contradictions
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 SIGMA
DEFINE Phase
–
–
–
–
INTRODUCTION TO DEFINE
ESTABLISH DESIGN PROJECT
FINANCIAL ANALYSIS
PROJECT MANAGEMENT AND RISK
ASSESSMENT
– SUMMARY; ISSUES TO CONSIDER
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 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 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 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 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 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 SIGMA
VERIFY Phase -- CUSTOM FEATURES
– PILOT TESTING
– FULL-SIZE SCALE-UP AND
COMMERCIALIZATION
– DESIGN INFORMATION AND DATA
MANAGEMENT
– LEAN MANUFACTURING
I- DESIGN FOR SIX SIGMA
 DMADV Training/Project Map
IDEAL
Training
15 - 16 Weeks
D-M
Weeks
1
Project
D-M
A
3
1
PP
A
D
4
1
DR-2
D
V
4-6
1
DR-3
V
DVT
Critical Success Factors:
• Project starts with training
• Project < 6 months
• Project phases match training schedule
19 - 22 Weeks
(5-6 Months)
4-6
DR-4
MVT
I- DESIGN FOR SIX SIGMA
 DMADV Training/Project Map
REAL
(A)
Project
Start
?
Training
Mass Production
DR-2
(B)
Training
Product Planning
D-M
OK
Project
Start
(C)
Start
(D)
Consulting
?
Training
Project
DR-3
No
Training
Gap
Project
Start
SIX SIGMA DMADV TRAINING FLOW
JURAN
Executive Briefing
4-8 hrs
Sr. Instructor
Preparations
JURAN
Champion Training/Workshop
2 days
Sr. Instructor
Go-No go Decision
DMADV
Black Belt Training
Black Belt Project
Define/Measure
D/M
Analyze
A
Design
D
Verify
V
JURAN
INSTRUCTOR
(first wave)
Total Duration:
4-6 months
Trained Black Belt
?
No
Certified
Black Belt
Certification
Project
Yes
JURAN
Sr. INSTRUCTOR
Statistics, Finance
Master Black Belt Program
Master Black
Belt Project
Leadership Skills
Certified MBBs
Total Duration:
4-6 months
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DESIGN for SIX SIGMA - Welcome to Ideation TRIZ