Introduction to Structured Design and Process Improvement

Using a product and process of the class’s choice, students are taught the key steps that must be followed to design world class products and processes. Beginning with definition of customer needs and ending with defining the process characteristics that have to be controlled in order to produce product which meets the customer needs, students are provided with structured techniques that if followed will give the company the highest probability of achieving Six Sigma performance. The duration of the class is two days and designed for personnel who have design and/or production responsibilities.

Class Objectives

Teach students:

• The five fundamental reasons companies fail and how to prevent them;
• The concepts/interrelationships/benefits of System FMEA's (SFMEA), System Requirements, Product Requirements and Design Validation Plan & Reports (DVP&R);
• The concepts/interrelationships/benefits of System FMEA (SFMEA), Design Validation Plan Report (DVPR), Design FMEA (DFMEA) and Design Verification Plans & Report (DVP&R);
• How to apply Design FMEA (DFMEA) and Design Verification Plan & Report (DVP&R) creation techniques to a product of the class’s choice;
• The obstacles they will face in doing a System FMEA (SFMEA) and a Design FMEA (DFMEA) efficiently and how to overcome them including spending no more than 15 seconds on any rating;
• How to use the power and utility of a System FMEA (SFMEA) and a Design FMEA (DFMEA) information to improve product performance and reliability;
• How to design for Six Sigma;
• How to manage design risk for a project;
• The concepts/interrelationships/benefits of Design FMEA's (DFMEA), Specification Analysis, Process FMEA's (PFMEA) and Control Plans;
• How to develop a Specification Analysis, Process FMEA (PFMEA), and Control Plan for a product and process of the class’s choice so they can see the concepts applied;
• The obstacles they will face in doing Process FMEA's (PFMEA) efficiently and how to overcome them including spending no more than 15 seconds on any rating;
• How to use the Process FMEA (PFMEA) information to decrease defects, increase productivity and reduce downtime;
• How to manage production risk for a project.

Suggested Attendees

This class is for anyone who would like to learn new techniques to improve the performance and manufacturability of their designs as well as their manufacturing process capabilities.

Class Duration

The total duration for the class is two days. The class is approximately 35% instruction and 65% application exercises.