CONTENTS Preface xi Acknowledgments xiv 1 Introduction 1 Is Your Product Development Process Helping You Win the Game Today? Do You Even Have a Product Development Process? So How Does DFSS Work Its Magic? What We'll Promise You Do You Have the Gottawanna? 2 What Is Design for Six Sigma? 15 Introduction What Is Six Sigma? The Idea of Improving Design Processes What Is DFSS-Narrow Sense? What Is DFSS-Broad Sense? Key Points 3 What DFSS Can Do for You and Your Company 35 Introduction Financial Benefits of DFSS (for Senior Leaders) Reducing Internal Friction Through DFSS (for Middle Managers) DFSS Personal Benefits-WIIFM? (for Product Developers) One Company's Product Development Improvement Journey The Company Product Development History Our Product Development Infancy It's Hard to Grow Up Are We Adults Yet? Oops, A Few Steps Backward! OK, We're Out of the Nest Next Steps Key Points 4 DFSS: The Method and Roadmap 49 Introduction DMADVI: A Quick History and 50,000-Foot View Define Phase-Overview and Tools Measure Phase-Overview and Tools Analyze Phase-Overview and Tools Design Phase-Overview and Tools Verify and Validate-Overview and Tools Implement-Overview Tools 5 Gap Analysis and Readiness for the DFSS Journey 77 Introduction Why Do You Want to Do DFSS? Gap Analysis Quality-Side Gaps Gap Analysis-Current New Product Development Processes Gap Analysis-Current New Product Development Organizational Structure Team-by-Team Gap Analysis Prioritize the Development Process Improvements A-Side Gaps Leadership Commitment Tolerance and Motivation for Change Planning for Change Key Points: DFSS Gap Analysis 6 Planning, Leading and Implementing DFSS 107 Introduction Planning the Deployment Step 1. Define DFSS Goals and Charter Your DFSS Team Step 2. Understand Gaps and Prioritize Changes; Align the Organization Step 3. Plan the Changes Step 4. Pilot DFSS Changes, Measure Results, Roll Out Full-Scale Changes Step 5. Monitor and Improve the DFSS Process Step 6. Integrate and Sustain the Gains Do's and Don'ts to Successful DFSS Implementation Do's to Successful DFSS Implementation Don'ts to Avoid in Implementing DFSS Key Points: Using This Book to Help You Along in Your Implementation 7 Measuring Success 143 Introduction What and When to Measure DFSS Leading or Early Deployment Metrics DFSS Middeployment or In-Process Metrics DFSS Lagging, or Independence Metrics Planning to Measure Your DFSS Success DFSS Deployment Metrics Examples Who to Measure How to Measure Key Points: Guide to Measuring Success 8 How to Know When the Organization Has It 155 Identifying the Success of Training Benchmarking Success Against Other Organizations Verifying Independence Day Communicating Independence Day Key Points: How to Measure and Communicate Your Success 9 Keeping Up the DFSS Drive 163 Introduction Sustaining DFSS: Enablers and Enforcers Enablers Enforcers Ownership for the New Process Chapter Take-Aways: Maintaining the Success of DFSS 10 Where Do You Go from Here? 173 Introduction Advanced versus New Product Development Axiomatic Design Customer Listening Design Infrastructure Improvements Holistic Development Leaning the New Product Development Process Organizational Change Management Schedule Performance Improvement Supplier Development Systematic Innovation Technique Taguchi Robust Design Theory of Inventive Problem Solving (TRIZ) Key Points 11 DFSS Case Study 189 Introduction Define Phase-The Opportunity Measure Phase-Defining Customer Requirements and CTQs Analyze Phase-Identifying Concepts and Assessing Feasibility Design Phase-Detailed Product and Production Process Design Verify/Validate Phase-Verify Against Requirements; Validate Against Customer Needs Implement Phase-Production and Quality/Business Results Glossary 221 References 231 Index 233