Design for six Sigma Green Belt - Level 1
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Design for Six Sigma (DFSS) is an evolving advanced practice that can be applied to all kinds of products, services, and system designs to take process improvement to the next level. It is estimated that 70-80% of quality problems originate in product definition and design. One of the main themes of Design for Six Sigma (DFSS) is to move from reactive to predictive by designing quality into the product, instead of waiting until production starts and then finding and attempting to fix issues. In addition, DFSS can be an enabler for new product development.
Working in new product development is an exciting and enriching career, but also challenging. The Green Belt course is focused on improving your skills to succeed in this critical area. It examines key concepts and introduces proven tools to effectively translate customer requirements into functional requirements and then ultimately into more robust product, service, and process designs.
As many organizations improve their operational quality, they recognize the need to focus their quality improvement efforts on designing quality into their products and services. This Green Belt course, organized around the IDDOV Design for Six Sigma Methodology, examines methods and analysis tools for designing in quality to increase customer satisfaction and reduce downstream manufacturing quality and warranty concerns.
The IDDOV methodology involves identifying customer requirements, evaluating design concepts, and then optimizing new processes to meet the customer-driven design objectives. The tools and methods covered include Voice of the Customer Analysis, Balanced Design Scorecards, Transfer Functions, Failure Mode and Effects Analysis, TRIZ, Pugh Method, Hypothesis Testing, Tolerance Simulation and Analysis, and Product/Process Validation.
The Green Belt Level I course focuses on the core concepts and methods of applying the IDDOV methodology within the new product development process. In this course, all of the tools and analysis techniques covered use Microsoft Excel and Add-In templates that are included with the course.
This course involves viewing lecture modules, participating in student discussion boards, completing homework exercises, and case studies. The Green Belt Level I course is comprised of 24 modules which are detailed below. It involves 40-50 hours of material which students should be able to complete within 180 days or less.
- Course Introduction—New Product Development Challenges
- IDDOV Methodology/ Identifying Projects
- Defining Customer Requirements: Voice of the Customer
- Survey Analysis Methods
- Developing Functional Requirements/FAST Diagrams
- House of Quality
- Design Concept Generation
- Creativity and Innovation Tools
- TRIZ Overview
- Design Concept Selection: Design Scorecards, Pugh Matrix
- Design Failure Mode and Effects Analysis (DFMEA)
- Design Issue Countermeasures, DFX Analysis, Axiomatic Design
- Design Optimization: Transfer Functions, P-Diagrams, and Robustness
- Two Group Hypothesis Tests (t-test, F-test, 2 Proportion Tests)
- One Way ANOVA Tests
- Two Way ANOVA Tests
- Problem Solving Session: Hypothesis Tests
- Tolerance Analysis: Statistical Tolerance Methods
- Tolerance Simulation: Development and Allocation
- Problem Solving Session: Tolerance Simulation
- Product Design Verification and Validation
- Process Validation
- Course Summary
Who should attend
The Design for Six Sigma Green Belt Level I course is aimed primarily at Product Designers, Manufacturing Engineers, and Project Managers working in new product development.