Book description
Use Six Sigma to achieve and sustain excellence in product development and commercialization!
To sustain growth and profitability, companies must tightly align product development and commercialization to fast-changing customer requirements. In this book, Clyde Creveling identifies the four process areas most crucial to doing so—and shows executives and managers how to optimize each of them.
Creveling introduces a Six Sigma-enabled workflow that encompasses strategic product/technology portfolio definition and development, research and technology development (R&TD), tactical design engineering processes for commercialization, and operational production and service support. He presents tools, methods, and best practices for selecting the right projects, prioritizing them, and executing them rapidly, consistently, and successfully.
Integrate all key technical processes so they work together in harmony
Create Phase/Gate control plans for delivering products with minimal risk
Establish scorecards for risk management in technical processes
Use Six Sigma tools, such as Monte Carlo and FMEA, to improve project management
Bring discipline to your product and technology portfolio renewal processes
Systematically optimize your commercialization processes
Define stripped-down “Fast Track” processes for commercializing high-risk, high-reward opportunities
Provide effective operational support after you launch your product
Preview the future of “lean” and Six Sigma in technical processes
Use lean techniques to streamline repeatable processes such as R&D, product design, and post-launch production engineering support
Learn how to manage the risk of doing a fast track commercialization project when you really must cut corners to get a product out into the market before your opportunity evaporates
Foreword by John Boselli xiii
Preface xv
About the Author xxi
Chapter 1: Introduction to Six Sigma for Technical Processes 1
Chapter 2: Scorecards for Risk Management in Technical Processes 21
Chapter 3: Project Management in Technical Processes 35
Chapter 4: Strategic Product and Technology Portfolio Renewal Process 51
Chapter 5: Strategic Research and Technology Development Process 95
Chapter 6: Tactical Product Commercialization Process 163
Chapter 7: Fast Track Commercialization 275
Chapter 8: Operational Post-Launch Engineering Support Processes 293
Chapter 9: Future Trends in Six Sigma and Technical Processes 317
Glossary 323
Index 351
Table of contents
- Copyright
- Prentice Hall Six Sigma For Innovation and Growth Series
- Prentice Hall Six Sigma For Innovation and Growth Series
- Foreword
- Preface
- About the Author
- 1. Introduction to Six Sigma for Technical Processes
- 2. Scorecards for Risk Management in Technical Processes
-
3. Project Management in Technical Processes
- Six Sigma Contributions to Project Management in Technical Processes
- Designing Cycle-Time: Critical Paths of Key Technical Tasks/Toolsets by Phase
- Nine Key Steps
- Modeling Technical Task Cycle-Time Using Monte Carlo Simulations
- Documenting Failure Modes in the Critical Paths of Technical Tasks by Phase
- Integrated Project Plan
- 4. Strategic Product and Technology Portfolio Renewal Process
-
5. Strategic Research and Technology Development Process
- Six Sigma–Enhanced Research and Technology Development
- The I2DOV Roadmap: Applying a Phase-Gate Approach to Research and Technology Development
-
I2DOV Phase 1: Invent/Innovate Technology Concepts
-
I2DOV Phase 1: Invention and Innovation Tasks
- Construct Technology Roadmaps and Document Technology Trends
- Gather and Translate “Over-the-Horizon” Voice of the Customer
- Define Product Line Strategies (PLS) and Family Plans
- Create Technology Houses of Quality
- Conduct Technology Benchmarking
- Generate Technology System Requirements Document
- Define Functions That Fulfill the Technology Requirements
- Enable Support and Conduct Invention (Generate New Knowledge)
- Enable, Support, and Conduct Innovation (Enhanced/Leveraged Reuse of Existing Knowledge)
- Refine, Link, and Document Discoveries, Learning, and Basic Models to PLS
- Transfer Refined, Linked, and Documented Knowledge into Technology Concept Design
- Generate Technology Concepts That Fulfill the Functions
- Generate Risk Assessments and Summary Profile
- Generate Development Phase Project Plan
- A General List of Phase 1 Tools, Methods, and Best Practices
-
I2DOV Phase 2: DEVELOP Technology
- Generate and Refine Technology Concept-Evaluation Criteria
- Evaluate and Select Superior Technology Concepts
- Analyze, Characterize, Model, and Stabilize Nominal and Tunable Performance of Superior Technology
- Conduct SPC and Capability Studies under Nominal Conditions to Certify and Prepare Superior Technology Models and Prototypes to Take into Optimization
- A General List of Phase 2 Tools, Methods, and Best Practices
-
I2DOV Phase 3: Optimization of the Robustness of the Baseline Technologies
- Review and Finalize CFRs for the New Subsystem Technologies
- Develop Subsystem Noise Diagrams and Platform Noise Maps
- Conduct Noise Factor Experiments
- Define Compounded Noises for Robustness Experiments
- Define Engineering Control Factors for Robustness Development Experiment
- Design for Additivity and Run Designed Experiment
- Analyze Data, Build Predictive Additive Model
- Run Verification Experiments to Certify Robustness
- Document Critical Functional Parameter Nominal Set Points and CFR Relationships
- A General List of Phase 3 Tools and Best Practices
-
I2DOV Phase 4: Verification of the Platform or Sublevel Technologies
- Integrate Subsystems into Platform or Product Test Fixtures
- Refine and Confirm “Between and Within” SS CFRs
- Develop, Integrate, and Certify Platform Data-Acquisition Systems
- Design Platform or Integrated SS Nominal Performance Tests
- Conduct Nominal Performance Tests
- Evaluate Data Against Technology Requirements
- Design Platform or Integrated Subsystem Stress Tests
- Conduct Stress Tests
- Perform ANOVA on Data to Identify Sensitivities
- Refine and Improve Platform or Integrated Subsystem Performance
- Rerun Stress Tests and Perform ANOVA on Data to Verify Reduced Sensitivities
- Conduct Reliability Evaluations for New Subsystems Technologies and Platforms
- Document CFPs and CFR Relationships and Certify That the Technology Is Transferable
- A General List of Phase 4 Tools and Best Practices
-
I2DOV Phase 1: Invention and Innovation Tasks
-
References
-
6. Tactical Product Commercialization Process
- Six Sigma–Enhanced Product Commercialization
- Preparing for Product Commercialization
- Defining a Generic Product Commercialization Process Using the CDOV Roadmap
-
The CDOV Process and Critical Parameter Management during the Phases and Gates of Product Commercialization
-
Concept Phase: Develop a System Concept Based on Market Segmentation, the Product Line, and Technology Strategies
- Gather the Specific Voice of the Customer by Market Segment for the Idea Bounded by the Project Being Activated from the Portfolio
- Refine and Rank the Voice of the Customer Using KJ Analysis
- Create Product- or System-Level House of Quality
- Conduct Competitive Product Benchmarking
- Generate Product- or System-Level Requirements Document
- Design Functions That Fulfill the System Requirements
- Generate System Concept-Evaluation Criteria
- Generate System Concepts That Fulfill the Functions
- Evaluate System Concepts
- Select Superior System Concept
- Analyze, Characterize, Model, and Predict Nominal Performance of the Superior System
- Develop Reliability Requirements and Initial Reliability Model for the System
- Gate 1 Readiness
- Prerequisite Information to Conduct Phase 1 Activities
- General Phase 1 Gate Review Topics
- General List of Phase 1 Tools and Best Practices
-
Design Phase: Design Subsystem-, Subassembly-, and Part-Level Elements Based on System Requirements
- Create Sublevel Houses of Quality
- Conduct Sublevel Benchmarking
- Generate Sublevel Requirements Documents
- Develop Functions That Fulfill the Sublevel Requirements
- Generate Sublevel Concept-Evaluation Criteria
- Generate Sublevel Concepts That Fulfill the Functions
- Evaluate Sublevel Concepts
- Select Superior Sublevel Concepts
- Analyze, Characterize, Model, Predict, and Measure Nominal Performance of Superior Sublevel Designs (including DFMA, Initial Tolerances, and Cost Analysis)
- Analysis, Characterization, and Modeling in the Design Phase
- Measurement Systems in the Design Phase
- Produceability in the Design Phase
- Develop Reliability Model and FMEA for Each Sublevel Design
- Design Process Steps Down to the Subassembly, Component, and Manufacturing Process Levels
- Gate 2 Readiness
- Phase 2 Gate Review Topics
- A General List of Phase 2 Tools, Methods, and Best Practices
-
Concept Phase: Develop a System Concept Based on Market Segmentation, the Product Line, and Technology Strategies
-
The CDOV Process and Critical Parameter Management during the Phases and Gates of Product Commercialization
-
Optimize Phase: Optimize Sublevel Designs and the Integrated System
- Review and Finalize the Critical Functional Responses for the Subsystems and Subassemblies
- Develop Subsystem Noise Diagrams and System Noise Map
- Conduct Noise Factor Experiments
- Define Compounded Noises for Robustness Experiments
- Define Engineering Control Factors for Robustness-Optimization Experiments
- Design for Additivity and Run Designed Experiments
- Analyze Data and Build a Predictive Additive Model
- Run Verification Experiments to Verify Robustness
- Conduct Response Surface Experiments onCritical Adjustment Parameters
- Run Verification Experiments to Verify Tunability and Robustness Parameters for Subsystems and Subassemblies
- Document Critical Functional Parameter Nominal Set Points and CAP and CFR Relationships
- Develop, Conduct, and Analyze Reliability/Capability Evaluations for Each Subsystem and Subassembly
- Gate 3A Readiness
- A General List of Phase 3A Tools, Methods, and Best Practices
- Phase 3B: System Integration, Nominal Performance Evaluation, Robustness Optimization, and Initial System Reliability Assessment
- Integrate Sublevel Designs into System Test Units
- Verify Capability of the System-Wide Data-Acquisition System
- Conduct Nominal Performance Evaluation on the System
- Conduct System-Robustness Stress Tests
- Refine Subsystem Set Points to Balance System Performance
- Conduct Initial System Reliability Assessment
- Verify System Readiness for Final Product Design Capability Development and Assessment
- Document System Risk Profile
- Generate Verify Phase Project Plan
- Gate 3B Readiness
- Phase 3B Gate Review Topics
- A General List of Phase 3B Tools, Methods, and Best Practices
-
Verify Phase: Verification of Final Product Design, Production Processes, and Service Capability
- Conduct Final Tolerance Design on Components and Subsystems
- Place All CTF Components and CFRs under SPC in Supply Chain and Assembly
- Build Product Design Certification Units Using Production Parts
- Evaluate System Performance under Nominal Conditions
- Evaluate System Performance under Stress Conditions
- Complete Corrective Actions on Problems
- Evaluate System Performance and Reliability
- Verify That Product Design Meets All Requirements
- Develop Transfer Plan for the Critical Parameter Database for Production, Supply Chain, and Service Organizations
- Gate 4A Readiness
- Phase 4A Gate Review Topics
- A General List of Phase 4A Tools and Best Practices
- Phase 4B: Capability of Production, Assembly, and Manufacturing Processes within the Business as well as the Extended Supply Chain and Service Organization
- Build Initial Production Units Using Inspected Production Parts
- Assess Capability of All CFRs and CTFs in Production and Assembly Processes
- Assess Capability of All Product-Level and Sublevel CFRs During Assembly
- Assess Reliability of Production Units
- Verify That All Requirements Are Being Met across Assembly Processes
- Verify That All Requirements Are Being Met across Production Processes
- Verify That All Service Requirements Are Being Met with Service/Support Processes
- Verify That Product, Production, Assembly, and Service/Support Processes Are Ready for Launch
- Gate 4B Readiness
- Phase 4B Gate Review Topics
- A General List of Phase 4B Tools, Methods, and Best Practices
-
Optimize Phase: Optimize Sublevel Designs and the Integrated System
-
7. Fast Track Commercialization
- Six Sigma Applications for Fast Track Commercialization Projects
- DMAIC Six Sigma Project Capability to Support a Fast Track Project
- Technology Development Capability to Support Fast Track Projects
- 8. Operational Post-Launch Engineering Support Processes
- 9. Future Trends in Six Sigma and Technical Processes
- Glossary
Product information
- Title: Six Sigma for Technical Processes: An Overview for R Executives, Technical Leaders, and Engineering Managers
- Author(s):
- Release date: November 2006
- Publisher(s): Pearson
- ISBN: 9780132382328
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