Design for Six Sigma Certification

WHAT IS DFSS?

Six sigma as a science for systematic problem solving was born in Motorola with a principal aim to improve an existing product/process to achieve closer to zero defects. The DMAIC methodology provided a systematic framework for analyzing the variability in a process and identifying root causes which will eventually improve the product quality. It is believed that although achieving Six Sigma level of quality i.e. 3.4 defects per million opportunity, is feasible in theory but in practice many product’s quality could not be improved beyond 4.5 sigma (1350 DPMO). This is due to the fact that there are significant numbers of manufacturing process variations or the result of errors in the product and process design which could not be corrected on the shop floor.

Achieving six sigma level of quality is feasible only when the product design / development process takes care of eliminating design errors at a very early stage of product development. In essence, the excellence in manufacturing alone cannot help achieve zero defects; excellence in design is also required to achieve this target.

The traditional product development process has limited capability to achieve first-time right new products. In order to challenge the traditional product development process, and to achieve zero defects in design, a science called ‘Design for Six Sigma’ was developed by automobile and aircraft manufacturing industries and has become a perfect science today with a well structured product development process called IDOV (Indentify-Design-Optimize-Verify).

COURSE CONTENT

• New Product Introduction
• Customer need identification
• Benchmarking
• Quality Function Deployment (QFD)
• Concept generation solutions
• Failure mode effect analysis (FMEA)
• Robust design
• Design for Manufacturing & Assembly (DFMA)
• Reliability Assessment
• Control Planning

Learning outcomes

• Implement DFSS methodology for developing new products with shortest lead-time, zero defects and lowest cost
• Use the IDOV Approach (Identify Design Optimize Verify) approach for designing first time right products

Target audience

This program is recommended for people from both service as well as manufacturing industry:

• Design Engineers
• Product Designers
• Chief Designers
• R & D engineers
• Production engineers
• QA engineers

No. of days : 8

TRAINING METHODOLOGY                              

• Lecture
• Group discussion
• Simulation with a hands on application of DFSS methodology
• Hands-on application of tools and techniques
• Quiz at the end of each sessions
• Objective type open book exam at the end of four days
• Faculty & course evaluation by participants through feedback
• Every day feedback from the participants for course correction on the next day

COURSE CERTIFICATE
The Following are the criteria for evaluation of the Participants:

• Faculty assessment of the participants
• Exam scores – minimum 70% to qualify.
• Attendance to the training program