Showing papers on "Design for Six Sigma published in 2018"

Lean Six Sigma with environmental focus: review and framework

Abstract: Lean Six Sigma enables contemporary manufacturing organizations to attain waste elimination and defect reduction. As manufacturing systems are becoming environmentally sustainable, Lean Six Sigma framework needs to be integrated with sustainability tools to enable environmental and operational benefits. The purpose of this article is to review the literature on Lean Six Sigma from six different perspectives pertaining to manufacturing firms. A qualitative type of review methodology was adopted for conducting the review. Research articles related to the topic were collected from leading journal databases. Further, literature analysis was also performed on Lean Six Sigma with environmental focus. A total of 70 research articles that are in line with the research were selected and reviewed. Based on the insights obtained from analysis, a generic framework for implementation of Lean Six Sigma with environmentally benign tools was developed. The developed framework incorporates environmental aspects while implementing Lean Six Sigma which helps in reducing cost, wastes, environmental impacts, and other inefficiencies associated with the manufacturing process. This review article highlights the insights on Lean Six Sigma by conducting a systematic review pertaining to manufacturing firms and development of a generic framework that incorporates environmental focus into the Lean Six Sigma framework. This article enables researchers in developing knowledge on the concept of Lean Six Sigma with environmental focus and also helps them to formulate and implement Lean Six Sigma concepts to attain operational and environmental benefits.

Robust Tolerance Design Optimization of a PM Claw Pole Motor With Soft Magnetic Composite Cores

Abstract: In the past decades, various methods have been investigated for assessing performance variation and robust optimization for electromagnetic device design under uncertainties and/or tolerances. However, in actual production, the manufacturing tolerances are variable to a certain extent, which can be optimized for integrating the performance, manufacturing cost, and production quality. This paper proposes a tolerance design optimization approach by optimizing the design parameters and tolerances simultaneously based on design for six sigma technique. A permanent magnet claw pole motor with soft magnetic composite cores is optimized by using the proposed approach. For this high-dimensional optimization problem involving electromagnetic and thermal performance, Kriging model and 3-D thermal network model are employed under the multilevel framework for increasing the optimization efficiency. Finally, through the analysis, the proposed robust tolerance optimization method shows good performance with improved motor performance as well as the diversity controlling without cost increasing.

How does Six Sigma influence creativity and corporate performance through exploration and exploitation

Abstract: While Six Sigma has been implemented increasingly in a wide range of industries, little empirical research has been conducted on its effects on individual creativity and project performance. Many managers still trust that Six Sigma provides structured methods, such as DMAIC (define, measure, analyse, improve, and control) and DFSS (design for Six Sigma), by which individuals can organise their creative ideas to improve project performance. Once project performance improves significantly, it is certain that corporate performance improves significantly as well. However, no empirical studies support this premise. Therefore, this study assessed a new research model in which the structured methods provided by the Six Sigma philosophy can help individuals organise their exploration and exploitation to support their creativity and improve project performance that leads ultimately to corporate performance. To confirm the research model proposed, survey questionnaire data were collected from 201 respondents (the m...

Advanced Design Applied to an Original Multi-Purpose Ventilator Achievable by Additive Manufacturing

Abstract: Considering the progressively expansive trade world, “time to market” of productions and goods has turned into a key element for business accomplishment. There are diverse practices that antedate design faults and unveil products on the market in minus time. Among the most used methods in the design and explanation of the necessities, quality function deployment (QFD) and design for Six Sigma (DFSS) can be used. In the prototyping stage, it is probable to address the emergent technology of additive manufacturing. Today, 3D printing is employed as a quick prototyping technique. Nevertheless, the tangible task which industry is fronting is the adoption of these machines for large-scale production of components, which is now possible with new HP multi fusion. The goal of this paper is to illustrate the entire product development process taking advantage of the most modern models and technologies for the final realization of a case study that involves the design and prototyping of an innovative multifunctional fan (lamp, aroma diffuser, and fan) through the multi jet fusion of HP. To begin with, issues related to the DFSS, the QFD and their application to identify the fan requirements are explored. Once the requirements have been defined, the modern CAD design systems and the CAE systems for the validation of the case study will be analyzed and applied. Finally, HP’s multi jet fusion methodology and design rules for additive manufacturing will be analyzed in detail, trying to exploit all the positive aspects it offers.

Optimum design for intake and exhaust system of a heavy-duty diesel engine by using DFSS methodology

Abstract: In this study, an optimum design for intake and exhaust system of a heavy-duty diesel engine was conducted by using the well-known design for six sigma (DFSS) methodology As a result of this work, the NOx emission regulation has been successfully satisfied while minimizing the fuel consumption On the basis of this DFSS work, the design robustness of the engine system was also enhanced Hence, it is expected that the final design proposal would reduce the variability in brake thermal efficiency (BTE) that could be caused by the harsh environment and the system aging Especially, this work has successfully raised the amount of exhaust gas recirculation (EGR) up to the target level by adopting the venturi tubes in the intake and exhaust lines In this study, engine cycle simulation technique was employed to assess the effect of the various design parameters and the final design proposal was verified through a real engine test The current optimum design work has considered four control factors such as the size of turbocharger, the diameter of intake and exhaust venturi pipes, and the efficiency of EGR cooler Here, an L9 orthogonal array was employed to efficiently choose the best design proposal among 81 design combinations (ie, four independent control factors which individually have three different levels)

Design for six sigma: A review

Abstract: Article history: Received: September 2, 2017 Received in revised format: Sep-

Application of Design for Six Sigma tools in telecom service improvement

Abstract: Six Sigma is a systematic methodology aiming at operational excellence Under the general umbrella of Six Sigma, DMAIC and Design for Six Sigma are usually be implemented to improve product and process quality Facing quality bottlenecks in traditional improvement projects, tools in Design for Six Sigma is an efficient way to achieve better results In this paper, to meet the high-quality requirement of key clients, a telecom service system improvement project is illustrated by redesigning troubleshooting and service delivery processes in company Shanghai Telecom Co Ltd (ST) with the aid of some Design for Six Sigma tools Company ST improved its service system performance and obtained significant economic benefits from this project implementation Four key factors that affect the success of Design for Six Sigma tools application in improvement projects are discussed at last

Design of a combined tube feeding and cutting mechanism using design for six sigma approach

Abstract: Design for Six Sigma (DFSS) is a proactive approach that aims at designing inquality during the early stages of product or process development In this paper, theDMADV (Define-Measure-Analyze-Design-Verify) methodology has been applied toan industrial process The considered application involves cutting tubes topredefined lengths in order to be supplied to custom-made automotive exhaust tubemanufacturers Investigating the process reveals several problems that adverselyaffect the production Accordingly, customer requirements have been identified andthe Quality Function Deployment (QFD) has been implemented to translate theserequirements into technical characteristics A conceptual design of a compoundmechanism for both feeding and cutting has been suggested to overcome thedrawbacks in the current practice A detailed 3D CAD model has been developed, inaddition to a prototype that has been manufactured to test the validity of theproposed design Pilot runs of the prototype reveal that the developed mechanismnot only performs its intended task adequately, but also the chances of cutting wrongtube lengths have been eliminated

Simulation-based Six Sigma value function for system-level performance assessment and improvement

Abstract: Purpose The purpose of this paper is to develop a simulation-based value function (VF) that combines multiple key performance indicators (KPIs) into a unified Sigma rating (SR) for system-level performance assessment and improvement. Design/methodology/approach Simulation is used as a platform for assessing the multiple KPIs at the system level. A simple additive VF is formed to combine the KPIs into a unified SR using the analytical hierarchy process and the entropy method. Value mapping is utilized to resolve the conflict among KPIs and generate a unified value. These methods are integrated into the standard Six Sigma define-measure-analyze-improve-control (DMAIC) process. Findings Simulation results provided the Six Sigma DMAIC process with system-level performance measurement and analysis based on multiple KPIs. The developed VF successfully generated unified SRs that were used to assess various performance improvement plans. Research limitations/implications The accuracy and credibility of the results obtained from using the proposed VF are highly dependent on the availability of pertinent data and the accuracy of the developed simulation model. Practical implications The proposed approach provides Six Sigma practitioners and performance mangers with a mechanism to assess and improve the performance of production and service system based on multiple KPIs when conducting Six Sigma studies. Originality/value This paper contributes to the previous research by handling multiple KPIs in Six Sigma studies conducted at the system level using simulation and VF. The research also provides guidelines for using the different methods of weights assessment to form the VF within the DMAIC process.

Research on dynamic characteristics and fatigue robust optimization of integrated vehicle model

Abstract: This paper investigates the dynamic characteristics and fatigue robust optimization of heavy-duty tractor. First, this paper presents a vehicle model with sub-structure method. Based on the theory ...

To Priority the Success Factors in the Design of Progressive Die by DFSS Methodology

Abstract: As the industrial era progressed, the need for mass production is more sensed. Progressive die is widely used for mass production of sheet metal components due to its high productivity, high precision and relatively economic cost in terms of per piece of product. Progressive dies perform a series of fundamental cutting and forming operations typically on continuous sheet metal strip, or coil, stock. These operations are performed simultaneously at two or more stations during each press stroke as the strip progresses through the die to produce a part. Design of progressive die is a complex and highly specialized procedure, so designer progressive die must have a high level of knowledge on the part that can only be achieved through years of practical experience. Checking the design features of sheet metal parts, design of strip-layout, selection of die components, selection of materials for die components; and modelling of die components and die assembly are major activities for designing a progressive die. The traditional methods of carrying out these tasks require expertise and are largely manual and therefore tedious, time consuming and error-prone. The quality of die design depends to a large extent on the designer’s skill, experience and knowledge. This research attempts to study and priority the designing stages of progressive die by DFSS methodology (IDOV model). By focusing on the important stages, we can reduce the cost, the time of delivery and increase the quality and obtain the success factors.

Thermal Design for Six Sigma of an Imaging Device with Dynamic Thermal Management

Abstract: Imaging devices are a growth market in today’s economy. They are used as the eyes of many remote surveillance applications, in manufacturing and in logistics operations. One of the advantages of remote vision applications is the possibility to operate outside the human temperature range and in harsh environments. This poses new challenges for the thermal management of these devices as electronics have to operate reliably at higher ambient in sealed enclosures. Dynamic Thermal Management (DTM) scenarios are extensively used both in image sensors and in video processors to prevent operation at overtemperature. At high system environments, the temperature difference between system ambient and maximum component temperature become small, and the error in the on-chip temperature sensors becomes important. Previous work has shown the applicability of Design for Six Sigma methodology in thermal design. The effects of variability have so far not been considered as by nature CFD simulations are free from measurement errors. New insight recognises the error in the DTM temperature sensor as a source of variability. In addition, the heat dissipations are not fixed but use case (software) dependant. The present work uses DfSS tools to investigate system level performance and reliability including the errors in the on-chip DTM sensor and variability of in-use heat dissipation. The work shows that the variability results a bandwidth rather than a sharp boundary around the usage envelope. If this bandwidth becomes too wide, behaviour becomes erratic and DTM can contribute to lower reliability.

Lean design for six sigma: an integrated approach to achieving product reliability and low-cost manufacturing.

Abstract: The aim of this study is to discuss new product development based on a traditional stage-gate process and to examine how new product development [NPD] tools, such as lean design for Six Sigma, can accelerate the achievement of the main goals of NPD: reliable product quality, cost-effective implementation, and desired time-to-market. These new tools must be incorporated into a new approach to NPD based on the Advanced Product and Quality Planning methodology.

Lean Design in Healthcare: A Journey to Improve Quality and Process of Care

Abstract: This book gives the reader an inside look at creating a new healthcare service using practical examples and scenarios one would face if doing it themselves. This book chronicles the journey of a fictitious healthcare delivery organization using the Simpler Design System principles based on Lean methodologies. While the characters and actual story is fictitious, it is based on the journey many healthcare systems and clients have taken, the issues they have faced, and the successes and failures they’ve had. Tools and approaches used are based on the actual work of Simpler. The story format engages readers and is intended to motivate and inspire executive teams to use the tenets of the book as a guide to launch their own successful implementation of an idea-to-launch methodology. Tools include those gleaned from actual application of Lean Product Development, Agile, Design for Six Sigma, and Design Thinking Principles. Through engaging storytelling and practical theory, this book is written from the perspective of a physician leader that agrees to be the executive sponsor for a service redesign. As the story progresses, the sponsor becomes fascinated with the process and becomes the first VP of Innovation within his organization.

Analysis of design tool attributes with regards to sustainability benefits

Abstract: The trend of global manufacturing competitiveness has shown a significant shift from profit and customer driven business to a more harmonious sustainability paradigm. This new direction, which emphasises the interests of three pillars of sustainability, i.e., social, economic and environment dimensions, has changed the ways products are designed. As a result, the roles of design tools in the product development stage of manufacturing in adapting to the new strategy are vital and increasingly challenging. The aim of this paper is to review the literature on the attributes of design tools with regards to the sustainability perspective. Four well-established design tools are selected, namely Quality Function Deployment (QFD), Failure Mode and Element Analysis (FMEA), Design for Six Sigma (DFSS) and Design for Environment (DfE). By analysing previous studies, the main attributes of each design tool and its benefits with respect to each sustainability dimension throughout four stages of product lifecycle are discussed. From this study, it is learnt that each of the design tools contributes to the three pillars of sustainability either directly or indirectly, but they are unbalanced and not holistic. Therefore, the prospective of improving and optimising the design tools is projected, and the possibility of collaboration between the different tools is discussed.

The use of DFSS tool / design for six sigma in the innovative process of new product development: a case study

Abstract: The SS methodology is being widely used as a quality management model. Focusing on "Zero Defects" production, the tool that support DNP used in the planning phases, that precede manufacturing is DFSS methodology, suitable for production processes with SS requirement. There is a contradictory question regarding the differences and complementarities between DFSS tool and the SS methodology: to conclude about what is the best strategic decision by two companies, in which one uses the SS and the other uses the DFSS; else more, if it would be a competitor at a higher level with regard to the experience and knowledge, by using both. The case study indicates that given the intrinsic characteristics of the company, common to other Portuguese Small, Medium Enterprises (SMEs), it is clear that the use of DFSS tool turns out to be the most effective, especially when the client is a big company. Keywords: Design for Six Sigma (DFSS); New products development; Six Sigma (SS).

Design method for new-energy vehicle electronic product circuit

Abstract: The invention discloses a design method for a new-energy vehicle electronic product circuit. The method comprises the steps of 1, recognizing a microcontroller and a CAN transceiver; 2, defining the microcontroller and the CAN transceiver; 3, developing the microcontroller and the CAN transceiver; 4, optimizing a voltage stabilizer; 5, verifying the voltage stabilizer. According to the design method for the new-energy vehicle electronic product circuit, due to the DFSS design method, the method quite conforms to the characteristics and requirements for new-energy vehicle electronic product development, by means of the DFSS design, the product quality can be ensured, the requirement of a client is met, and meanwhile the product cost can be greatly lowered. The DFSS design method is imperative for comprehensive popularization in the field of new-energy vehicle electronic product design.

Improve the operating performance of sea water system in med/tcd unit in egypt usingsix sigma method

Abstract: The purpose of this paper is to establish a maintenance program for the sea water System as a critical part from Desalination Unit type (MED/TCD), to satisfy all requirements needed as the main supplier for most of the systems in the desalination unit, improve the performance of desalination unit, and increase the life time of its components. The methodology/approach – by applying the scientific method (four step method) plus the PDCA cycle, it means we apply the Six Sigma philosophy. To improve the performance of the multi effects Desalination unit and increase the operational lifetime, we will work on one of the critical system in the MED/TCD unit (Sea Water System SWS) establishing maintenance program using the Six Sigma philosophy, define, measure, analyze, improve, and control (DMAIC) method for problem-solving methodology in MED/TCD Unit, to increase the Reliability and Availability of the MED/TCD Unit and increase the unit lifetime. Keywords: Six Sigma, Multi Effect Desalination, Sea Water System, Reliability Centered Maintenance, Plan-Do-Check-Act Cycle, Reliability, Availability. Abbreviations:- SWS Sea Water System. PDCA plan – Do – Check – Act Cycle. MED Multi Effect Desalination. MED/TCD Multi Effect Desalination/ Thermo-compression Desalination. DMAIC Define – Measure – Analysis – Improve – Control Cycle. RCM Reliability Centered Maintenance. PMP Preventive Maintenance Program. IMS Integrated Management System. DPMO Defects Per Million Opportunity. DOE Design Of Experiment . DFSS Design For Six Sigma. PHE Plate Heat Exchanger. SIPOC Supplier, Inputs, Process, Outputs, and Customers . CTQ Critical To Quality. ANOVA Analysis Of Varience. DPU Defects Per Unit. RCMP Reliability Centered Maintenance Program.