example of dfss project
DESCRIPTION
If you think the DFSS phase-gate methodology is similar to DMAIC, then chances are you\'ve never really implemented or applied DFSS in the real world. This 29-slide presentation gives you an example of what DFSS really looks like.TRANSCRIPT
April 21, 2010: Version 6
Case Study of the Securekey Project
by Ray Balisnomo
DFSS in New Product Development
Synopsis of DFSS Method2
Define
Measure
Analyze
Design
Optimize
Verify
Project goals Customer analysis Create team
Capture voice of the customer Determine project schedule Review risk assessment
Develop CTQs Determine project schedule Review risk assessment
Develop models Review CTQs
Review CTQs Test tolerances Optimize design
Compare product to initial specs Document development
This DFSS Approach is NOT Practical
Synopsis of DFSS Method3
DFSS Design Scorecard
Critical to Quality (CTQ) Management
Quality Function Deployment (QFD)
Customer Needs
System Design
Subsystem Design
Component Design
Process Design
Process Capability
Component Capability
Subsystem Capability
System Capability
Customer Satisfaction
We use the other DFSS Tools (e.g., DOE, Regression, Pugh matrix, ANOVA, etc.) to close the gap between what the customer desires & how the actual product performs..
DFSS in Practice at Ingersoll Rand
Pred
ictV
alid
ate
Synopsis of DFSS Method4
Customer surveys or interviews
(Focus Groups)
MarketingRequirements Document
Kano Analysis
AHP Pair-wise Comparison
Quality Function Deployment
(HOQ-1)
System-level CTQ’s.HOW do we measure success?
Prioritized or WeightedCustomer Needs (WHAT’s)
Performance needs
Excitement needs or Delighters
Basic Needs (e.g., Test Requirements)
Product Specifications
Imp
orta
nc
e o
f the
WH
AT
s (A
HP
) 1
5 1
4
3 5
1 0
Tim
e to
rek
ey
cy
lind
er
Plu
g p
ull s
tren
gth
Ke
y in
se
rtion
& e
xtra
ctio
n fo
rce
Nu
mb
er o
f rek
ey
s to
failu
re
Ke
y o
pe
ratin
g to
rqu
e
Nu
mb
er o
f life c
yc
les
1 2 3 4 5 6
Ou
r Cu
rren
t Pro
du
ct
1
Kw
ik S
et
2
Rie
lda
3
Be
st
4
Imp
rov
em
en
t Fa
cto
r 5
1 .2
0 .8
1 .2
1 .0
Ov
era
ll Imp
orta
nc
e
6
6 1 .2
3 .2
4 2 .0
1 0 .0
Pe
rce
nt Im
po
rtan
ce
7
5 2 .6
2 .7
3 6 .1
8 .6
Ma
x =
1.0
Ou
r Cu
rren
t Pro
du
ct
Kw
ik S
et
Rie
lda
Be
st
Min
= -1
.0
1
2
3
4
Dire c tio n o f Imp ro v e me n t 1
Ea s y to Re k e y
Hig h ly Se c u re
Op e ra te s Smo o th ly
Re k e y a b le Mu ltip le T ime s
1
2
3
4
Imp o rta n c e o f th e HOWs 1
52
.9
21
8.6
49
9.0
33
6.1
19
3.8
23
7.8
Pe rc e n t Imp o rta n c e o f th e HOWs 2
3.4
14
.2
32
.4
21
.8
12
.6
15
.5
Ma x = 3 2 .4
Pe rc e n t Imp o rta n c e o f th e HOWs
Min = 3 .4
Kwik s e t 4
Rie ld a 5
Be s t L o c k s 6
Ta rg e ts fo r Ou r Fu tu re Pro d u c t 7
1 2 3 4 5 6
T ra d e o ffs
Sy n e rg y 1 .0Co mp ro mis e -1 .0
Dire c tio n o f Imp ro v e me n t
Ma x imiz e 1 .0Ta rg e t 0 .0Min imiz e -1 .0
Sta n d a rd 9 -3 -1
Stro n g 9 .0Mo d e ra te 3 .0We a k 1 .0
New SecureKey
Co n c e p t Se le c tio n
Be tte r 1 .0Sa me 0 .0Wo rs e -1 .0
Synopsis of DFSS Method5
Critical to Quality (CTQ) Management
Quality Function Deployment (QFD)
Customer Needs
System Design
DFSS in Practice at Ingersoll Rand
Pred
ict
Synopsis of DFSS Method6
System Level Q.F.D.
I
mp
or
ta
nc
e
to
t
he
C
us
to
me
r
1
38
42
8
12
T
ime
t
o
re
ke
y
cy
lind
er
P
lug
p
ull
st
re
ng
th
K
ey
I
ns
er
tio
n
&
Ex
tr
ac
tio
n
Fo
rc
e
K
ey
O
pe
ra
tin
g
Fo
rc
e
N
um
be
r
of
C
yc
els
t
ill F
ailu
re
1
2
3
4
5
Ma
x
=
5.
0
Pe
rc
ep
tio
ns
o
f
Be
st
Pe
rc
ep
tio
ns
o
f
Kw
iks
et
Pe
rc
ep
tio
ns
o
f
Rie
lda
Min
=
0
.0
1
2
3
4
Dir ec t ion o f I m pr ov em ent 1
Eas y t o Rek ey
High ly Sec ur e
O per at es Sm oot hly
Rek ey ab le M ult ip le Tim es
1
2
3
4
I m por t anc e of Pr oduc t At t r ibut es 1
41
4
35
4
20
0
11
4
15
0
M ax = 414. 0
I m por t anc e of Pr oduc t At t r ibu t es
M in = 114. 0
Bes t Per f or m anc e 3
38
00
12
5
48
0K
3.
8
3.
2
Kwik s et Per f or m anc e 4
23
66
55
22
K
4.
2
2.
3
Rielda Per f or m anc e 5
27
45
30
32
0K
5.
2
3.
5
Tar get Va lues 6
38
00
30
50
0K
3.
5
2.
0
1
2
3
4
5
Tra d e o ffs
Sy ner gy 1. 0Com pr om is e- 1 . 0
Dire c tio n o f Imp ro v e me n t
M ax im iz e 1. 0Tar get 0. 0M inim iz e - 1 . 0
Sta n d a rd 9 -3 -1
St r ong 9. 0M oder at e3. 0W eak 1. 0
Synopsis of DFSS Method7
Pugh Matrix for Concept Selection
Synopsis of DFSS Method8
Critical to Quality (CTQ) Management
Quality Function Deployment (QFD)
Customer Needs
System Design
Subsystem Design
DFSS in Practice at Ingersoll Rand
Pred
ict
Synopsis of DFSS Method9
D
ire
ct
ion
o
f
Im
pr
ov
em
en
t
1
C
lea
ra
nc
e
bt
wn
T
on
gu
e
Pin
a
nd
R
S
ide
ba
r
E
nd
P
lay
b
tw
n
Ho
us
ing
a
nd
P
lug
C
lea
ra
nc
e
bt
wn
T
on
gu
e
Pin
a
nd
K
ey
R
ac
k
Pin
C
lea
ra
nc
e
wit
h
Plu
g
Slo
t
1
2
3
4
I
mp
or
ta
nc
e
of
P
ro
du
ct
At
tr
ibu
te
s
1
414
354
200
114
150
Ma
x
=
41
4.
0
Im
po
rt
an
ce
o
f
Pr
od
uc
t A
tt
rib
ut
es
Min
=
1
14
.0
B
es
t
Pe
rf
or
ma
nc
e
3
3800
125
480K
3. 8
3. 2
K
wik
se
t
Pe
rf
or
ma
nc
e
4
2366
55
22K
4. 2
2. 3
R
ield
a
Pe
rf
or
ma
nc
e
5
2745
30
320K
5. 2
3. 5
T
ar
ge
t
Va
lue
s
6
3800
30
500K
3. 5
2. 0
1
2
3
4
5
Dir ect ion of I m pr ovem ent 1
Tim e t o r ekey cylinder
Plug pull st r engt h
Key I nser t ion & Ext r act ion For ce
Key O per at ing For ce
Num ber of Cycels t ill Failur e
1
2
3
4
5
I m por t ance of t he Par t At t r ibut es 1
36
80
39
68
37
26
53
52
M ax = 5352. 0
I m por t ance of t he Par t At t r ibut es
M in = 3680. 0
Tar get Values 3
0.
00
5
in
0.
00
35
in
0.
01
85
in
0.
00
60
in
1
2
3
4
Dire c tio n o f Imp ro v e me n t
M axim ize 1. 0Tar get 0. 0M inim ize - 1. 0
Sta n d a rd 9 -3 -1
St r ong 9. 0M oder at e 3. 0W eak 1. 0
Sub-system Level Q.F.D.
Synopsis of DFSS Method10
Critical to Quality (CTQ) Management
Quality Function Deployment (QFD)
Customer Needs
System Design
Subsystem Design
Component Design
DFSS in Practice at Ingersoll Rand
Pred
ict
Synopsis of DFSS Method11
Dire
ction
of
Impr
ovem
ent
1
Rac
k Pin
Cou
nter
-bor
e Dia
met
er
Rac
k Pin
Cou
nter
-bor
e De
pth
Sur
face
Rou
ghne
ss o
f Re
com
binat
ing S
ideba
r
1 2 3
Im
port
ance
of
the
Part
Attr
ibute
s
13680
3968
3726
5352
Max
= 5
352.
0
Impo
rtan
ce o
f th
e Pa
rt At
tribu
tes
Min
= 36
80.0
Tar
get
Value
s
3
0. 005 in
0. 0035 in
0. 0185 in
0. 0060 in 1
2
3
4
Dir ect ion of I m pr ovem ent 1
Clear ance bt wn Tongue Pin and R Sidebar
End Play bt wn Housing and Plug
Clear ance bt wn Tongue Pin and Key
Rack Pin Clear ance wit h Plug Slot
1
2
3
4
I m por t ance of Pr ocess At t r ibut es 1
281.
7
260.
3
260.
3
M ax = 281. 7
I m por t ance of Pr ocess At t r ibut es
M in = 260. 3
Tar get Values 3
1 2 3
Dir ect ion of I m pr ovem ent
M axim ize 1. 0Tar get 0. 0M inim ize - 1. 0
St andar d 9- 3- 1
St r ong 9. 0M oder at e 3. 0Weak 1. 0
Component Level Q.F.D.
Synopsis of DFSS Method12
Critical to Quality (CTQ) Management
Quality Function Deployment (QFD)
Customer Needs
System Design
Subsystem Design
Component Design
o Design of Experiments
DFSS in Practice at Ingersoll Rand
Pred
ict
Synopsis of DFSS Method13
Design of Experiments: Recombinating Sidebar Spring Retention
Synopsis of DFSS Method14
Dire
ction
of
Impr
ovem
ent
1
Rac
k Pin
Cou
nter
-bor
e Dia
met
er
Rac
k Pin
Cou
nter
-bor
e De
pth
Sur
face
Rou
ghne
ss o
f Re
com
binat
ing S
ideba
r
1 2 3
Im
port
ance
of
the
Part
Attr
ibute
s
13680
3968
3726
5352
Max
= 5
352.
0
Impo
rtan
ce o
f th
e Pa
rt At
tribu
tes
Min
= 36
80.0
Tar
get
Value
s
3
0. 005 in
0. 0035 in
0. 0185 in
0. 0060 in 1
2
3
4
Dir ect ion of I m pr ovem ent 1
Clear ance bt wn Tongue Pin and R Sidebar
End Play bt wn Housing and Plug
Clear ance bt wn Tongue Pin and Key
Rack Pin Clear ance wit h Plug Slot
1
2
3
4
I m por t ance of Pr ocess At t r ibut es 1
281.
7
260.
3
260.
3
M ax = 281. 7
I m por t ance of Pr ocess At t r ibut es
M in = 260. 3
Tar get Values 3
1 2 3
Dir ect ion of I m pr ovem ent
M axim ize 1. 0Tar get 0. 0M inim ize - 1. 0
St andar d 9- 3- 1
St r ong 9. 0M oder at e 3. 0Weak 1. 0
Component Level Q.F.D.
.028.069
Synopsis of DFSS Method15
Critical to Quality (CTQ) Management
Quality Function Deployment (QFD)
Customer Needs
System Design
Subsystem Design
Component Design
o Design of Experimentso Gauge R& R
DFSS in Practice at Ingersoll Rand
Pred
ict
Synopsis of DFSS Method16
Measurement System Analysis: Surface Roughness(Ra) Lck.Sidebar
Synopsis of DFSS Method17
Critical to Quality (CTQ) Management
Quality Function Deployment (QFD)
Customer Needs
System Design
Subsystem Design
Component Design
o Design of Experimentso Gauge R& Ro Regression Analysis
DFSS in Practice at Ingersoll Rand
Pred
ict
Synopsis of DFSS Method18
Binary Logistic Regression to Determine Upper Spec. Limit for Surface Roughness for Locking Sidebar
Ra
Ra
e
efailureP
2730
2730
1)(
Synopsis of DFSS Method19
Dire
ction
of
Impr
ovem
ent
1
Rac
k Pin
Cou
nter
-bor
e Dia
met
er
Rac
k Pin
Cou
nter
-bor
e De
pth
Sur
face
Rou
ghne
ss o
f Re
com
binat
ing S
ideba
r
1 2 3
Im
port
ance
of
the
Part
Attr
ibute
s
13680
3968
3726
5352
Max
= 5
352.
0
Impo
rtan
ce o
f th
e Pa
rt At
tribu
tes
Min
= 36
80.0
Tar
get
Value
s
3
0. 005 in
0. 0035 in
0. 0185 in
0. 0060 in 1
2
3
4
Dir ect ion of I m pr ovem ent 1
Clear ance bt wn Tongue Pin and R Sidebar
End Play bt wn Housing and Plug
Clear ance bt wn Tongue Pin and Key
Rack Pin Clear ance wit h Plug Slot
1
2
3
4
I m por t ance of Pr ocess At t r ibut es 1
281.
7
260.
3
260.
3
M ax = 281. 7
I m por t ance of Pr ocess At t r ibut es
M in = 260. 3
Tar get Values 3
1 2 3
Dir ect ion of I m pr ovem ent
M axim ize 1. 0Tar get 0. 0M inim ize - 1. 0
St andar d 9- 3- 1
St r ong 9. 0M oder at e 3. 0Weak 1. 0
Component Level Q.F.D.
.028.069.92
Synopsis of DFSS Method20
DFSS Design Scorecard
Critical to Quality (CTQ) Management
Quality Function Deployment (QFD)
Customer Needs
System Design
Subsystem Design
Component Design
Component Capability
DFSS in Practice at Ingersoll Rand
Pred
ictV
alid
ate
o Design of Experimentso Gauge R& Ro Regression Analysis
Synopsis of DFSS Method21
D
ire
ct
ion
o
f
Im
pr
ov
em
en
t
1
C
lea
ra
nc
e
bt
wn
T
on
gu
e
Pin
a
nd
R
S
ide
ba
r
E
nd
P
lay
b
tw
n
Ho
us
ing
a
nd
P
lug
C
lea
ra
nc
e
bt
wn
T
on
gu
e
Pin
a
nd
K
ey
R
ac
k
Pin
C
lea
ra
nc
e
wit
h
Plu
g
Slo
t
1
2
3
4
I
mp
or
ta
nc
e
of
P
ro
du
ct
At
tr
ibu
te
s
1
414
354
200
114
150
Ma
x
=
41
4.
0
Im
po
rt
an
ce
o
f
Pr
od
uc
t A
tt
rib
ut
es
Min
=
1
14
.0
B
es
t
Pe
rf
or
ma
nc
e
3
3800
125
480K
3. 8
3. 2
K
wik
se
t
Pe
rf
or
ma
nc
e
4
2366
55
22K
4. 2
2. 3
R
ield
a
Pe
rf
or
ma
nc
e
5
2745
30
320K
5. 2
3. 5
T
ar
ge
t
Va
lue
s
6
3800
30
500K
3. 5
2. 0
1
2
3
4
5
Dir ect ion of I m pr ovem ent 1
Tim e t o r ekey cylinder
Plug pull st r engt h
Key I nser t ion & Ext r act ion For ce
Key O per at ing For ce
Num ber of Cycels t ill Failur e
1
2
3
4
5
I m por t ance of t he Par t At t r ibut es 1
36
80
39
68
37
26
53
52
M ax = 5352. 0
I m por t ance of t he Par t At t r ibut es
M in = 3680. 0
Tar get Values 3
0.
00
5
in
0.
00
35
in
0.
01
85
in
0.
00
60
in
1
2
3
4
Dire c tio n o f Imp ro v e me n t
M axim ize 1. 0Tar get 0. 0M inim ize - 1. 0
Sta n d a rd 9 -3 -1
St r ong 9. 0M oder at e 3. 0W eak 1. 0
Sub-system Level Q.F.D.
Synopsis of DFSS Method22
Tolerance Stack-ups using Monte Carlo Simulation
Synopsis of DFSS Method23
DFSS Design Scorecard
Critical to Quality (CTQ) Management
Quality Function Deployment (QFD)
Customer Needs
System Design
Subsystem Design
Component Design
Component Capability
Subsystem Capability
DFSS in Practice at Ingersoll Rand
Pred
ictV
alid
ate
o Design of Experimentso Gauge R& Ro Regression Analysis
Synopsis of DFSS Method24
System Level Q.F.D.
I
mp
or
ta
nc
e
to
t
he
C
us
to
me
r
1
38
42
8
12
T
ime
t
o
re
ke
y
cy
lind
er
P
lug
p
ull
st
re
ng
th
K
ey
I
ns
er
tio
n
&
Ex
tr
ac
tio
n
Fo
rc
e
K
ey
O
pe
ra
tin
g
Fo
rc
e
N
um
be
r
of
C
yc
els
t
ill F
ailu
re
1
2
3
4
5
Ma
x
=
5.
0
Pe
rc
ep
tio
ns
o
f
Be
st
Pe
rc
ep
tio
ns
o
f
Kw
iks
et
Pe
rc
ep
tio
ns
o
f
Rie
lda
Min
=
0
.0
1
2
3
4
Dir ec t ion o f I m pr ov em ent 1
Eas y t o Rek ey
High ly Sec ur e
O per at es Sm oot hly
Rek ey ab le M ult ip le Tim es
1
2
3
4
I m por t anc e of Pr oduc t At t r ibut es 1
41
4
35
4
20
0
11
4
15
0
M ax = 414. 0
I m por t anc e of Pr oduc t At t r ibu t es
M in = 114. 0
Bes t Per f or m anc e 3
38
00
12
5
48
0K
3.
8
3.
2
Kwik s et Per f or m anc e 4
23
66
55
22
K
4.
2
2.
3
Rielda Per f or m anc e 5
27
45
30
32
0K
5.
2
3.
5
Tar get Va lues 6
38
00
30
50
0K
3.
5
2.
0
1
2
3
4
5
Tra d e o ffs
Sy ner gy 1. 0Com pr om is e- 1 . 0
Dire c tio n o f Imp ro v e me n t
M ax im iz e 1. 0Tar get 0. 0M inim iz e - 1 . 0
Sta n d a rd 9 -3 -1
St r ong 9. 0M oder at e3. 0W eak 1. 0
Synopsis of DFSS Method25
Capability Studies: Plug Pull Strength
Synopsis of DFSS Method26
DFSS Design Scorecard
Critical to Quality (CTQ) Management
Quality Function Deployment (QFD)
Customer Needs
System Design
Subsystem Design
Component Design
Component Capability
Subsystem Capability
System Capability
DFSS in Practice at Ingersoll Rand
Pred
ictV
alid
ate
o Design of Experimentso Gauge R& Ro Regression Analysis
Synopsis of DFSS Method27
Product Scorecard for System Level CTQ’s Parts DPM Performance
DPM Process DMP
Time to Rekey Cylinder 538 0
Plug Pull Strength 0 631
Key Insertion & Extraction Force 838 425
Number Cycles till Failure Metric moved to the Reliability Scorecard
Sub-total 1376 1056
Total DPMO 2432Equivalent Sigma or Z-score (short-term) 4.3
Microsoft Office Excel Worksheet
Synopsis of DFSS Method28
DFSS Design Scorecard
Critical to Quality (CTQ) Management
Quality Function Deployment (QFD)
Customer Needs
System Design
Subsystem Design
Component Design
Component Capability
Subsystem Capability
System Capability
Customer Satisfaction
DFSS in Practice at Ingersoll Rand
Pred
ictV
alid
ate
o Design of Experimentso Gauge R& Ro Regression Analysis
Synopsis of DFSS Method29
Financial Benefit• Securekey because it’s sold as part of a complete lock
generates $250Million per month, or $8.33 Million per day.• As a stand-alone product, the key & cylinder generates at least
$70,000 a day in operating income or profit
Synopsis of DFSS Method30
Sajil Mathachan Kent Barker Scott Welsby Jason Clifford Brian WallsDesign Engineer &
Inventor
VAVE Engineer Leader of Design Team
Design Engineer Design Engineer
Security, Colorado
Congratulations Secure Key Teamon achieving DFSS Greenbelt CertificationTeam Members in Bangalore India (not pictured) : Ajeya Rao, Subashchandra Rai, and Jonah Pattar