Design for Six Sigma Green Belt (IDOV) Online Training

Course Structure

This self-paced course consists of 12 recorded sessions:

• • • Project and Study Definitions
      • Project opportunities
      • Project vs. Study
      • Initiating / Scoping projects and studies
      • Key elements of the project / study charter

• • • DFSS Scorecard
      • What is the DFSS scorecard?
      • The use and purpose of the scorecard
      • The 4 main components of the scorecard
      • Estimating DPU (defects per unit) and the 3 methods for estimation
      • Examples of a completed scorecard
      • Practice completing a scorecard using Quantum XL software

• • • Voice of the Customer
      • Understanding the voice of the customer (VOC)
      • Kanos Model and types of customer requirements
      • Steps for gathering and analyzing the voice of the customer
      • Introduction to Quality Function Deployment (QFD)
      • Building House of Quality #1

• • • Concept Generation and Selection
      • Generating design concepts
        • Function Analysis
        • FAST (Function Analysis Systems Technique)
        • Morphological Mapping
        • TRIZ (Theory of Inventive Problem Solving)
        • Axiomatic Design
      • Selection Design Concepts
        • Pugh Concept Selection

• • • Detailed Design (HOQ2)
      • Quick review of QFD for flowing Down the Voice of the Customer
      • Moving from HOQ1 to HOQ2
      • The what and why of HOQ2
      • Tips for constructing HOQ2 and prioritizing design parameters
      • Case study: Self-Heating Container

• • • Failure Mode and Effects Analysis (FMEA)
      • The what and why of FMEA
      • Types of FMEAs
      • Approaches for FMEA (KISS-FMEA, traditional FMEA)
      • Major components of an FMEA
      • Analyzing risk using the Risk Priority Number (RPN)
      • How to complete an FMEA using Quantum XL software
      • FMEA examples

• • • Expected Value Analysis (EVA)
      • What is a transfer function?
      • How do we obtain transfer functions?
      • The meaning of “expected value”
      • Expected value analysis (EVA)
        • What is it?
        • Why we use it?
        • Different ways to do EVA
        • What is needed for doing EVA in Quantum XL software
      • EVA examples

• • • Robust Design
      • What is robustness?
      • What are noise factors and sources of noise
      • Robust design and analysis strategies using DOE
        • “Inner Array” approach
        • “Outer Array” approach
      • Optimization strategies for robustness
      • Robust (parameter) design optimization using Quantum XL software
      • Robust design case study

• • • Tolerance Allocation and Sensitivity Analysis
      • The what and why of tolerance allocation
      • Examining the impact of reducing the variation of an input on the resulting output dpm (defects per million)
      • Performing sensitivity analysis to understand which inputs have the biggest contribution to the resulting output variation and dpm
      • Methods for reducing the standard deviation of inputs
      • Using a combination of robust design and tolerance allocation to improve a design
      • Practice exercises and case study

• • • Design for X-ability (DFX)
      • The what and why of DFX, and how it fits with DFSS
      • Examples of DFX principles for manufacturability, assembly, serviceability, maintainability, and reliability
      • DFX and mistake proofing
      • Introduction to Reliability

• • • Probability Distributions
      • Probability concepts
      • Two Discrete Probability Distributions
        • Binomial
        • Poisson
      • Two Continuous Probability Distributions
        • Normal
        • Exponential
      • Using probability distributions to predict the probability of meeting a customer requirement

• • • DFSS Summary
      • The goals, objectives, and benefits of DFSS
      • Review of the DFSS IDOV process – Identify, Design, Optimize, Validate
      • Deploying DFSS
        • Best Practices
        • Breaking down barriers
        • Generating competency
        • Certification criteria

At the end of each session, there is an associated 5-question quiz to test your knowledge and gauge your understanding of that topic.  To receive credit for module completion 4 out of 5 quiz questions need to be answered correctly.  Quizzes can be taken until a passing score is achieved.

As with all of our training, the objective of this course is to develop a comprehensive set of skills that will let you function effectively as a change agent in your company. You will learn the Design for Six Sigma body of knowledge, practice techniques for both quantitative and non-quantitative analysis, and gain the skills necessary to become a practitioner of the Design for Six Sigma methodology and toolset to prepare you to lead Design for Six Sigma studies within your organization.