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DFSS Methods

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Topic Description

DFSS Methods will provide the participant with the knowledge and skills related to several of the key practices pertaining to the field of Design-For-Six-Sigma, or DFSS as it is often called. The participant will learn the basics of Quality Function Deployment (QFD) and the role this methodology plays in the design process or quality improvement initiative. Of interest, the participant will not only be exposed the industrial applications of DFSS, but the commercial applications as well. In addition, the participant will discover how to design and execute a hierarchical capability forecast, often referred to as capability flow-down and capability flow-up. As such, this methodology is founded upon the principles of forward and reverse error propagation.

To this end, the student will learn how to roll-up various types of yield estimates and defect rates so as to forecast the total defects-per-unit (DPU) of a given product or service system. Conversely, the participant will also learn how to propagate a system level performance goal to the node level; thereby, allowing the is condition of capability to be contrasted to the need to be condition. Naturally, such a study is undertaken so as to establish a viable improvement plan (if the resultant capability gap is too large). This topic also covers the practice of tolerance analysis and optimization as well as Monte Carlo simulation methods, techniques and procedures.

Reinforcement of major concepts, techniques, and application is realized through exercises, scenarios, and case studies. The following prerequisite topics are listed in sequential learning order: Basic Statistics. Total instructional time for this topic is 3 hours and 59 minutes.

QFD Method - Explain how quality function deployment can be used to help identify design specifications
Capability Flow-Down - Describe how a capability flow-down can be used as a risk allocation and abatement tool
Capability Flow-Up - Describe how a capability flow-up can be used to analyze the reproducibility of a design
Tolerance Analysis - Demonstrate how the RSS method can be used to analyze assembly tolerances
Monte-Carlo Simulation - Explain how Monte-Carlo simulation can be used during the process of design