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Babcock Training Academy

We deliver world-class training in complex systems to AUS/NZ defence, government and high tech markets

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Babcock Training Academy
Level 10 70 Franklin Street Adelaide  SA  5000

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T:   +61 (0)8 8440 9507
F:   +61 (0)8 8312 3227
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Breakthrough Performance using Design for Six Sigma

Course Description

Target Audience

The intended audience is anyone who desires to become a practitioner of DFSS. Scientists, engineers, project management and operations staff from all domains (Defence, Mining, Utilities etc) will benefit from the use of this proven methodology.

The workshop is designed for participants who have a strong background in Design of Experiments (DOE), Measurement System Analysis (MSA), probability and basic statistics. This course is highly recommended for those who have completed the Operational Design of Experiments course

Course Outline

Introduction to Design for Six Sigma (DFSS)

The Identify, Design, Optimize, Validate (IDOV) Methodology

DFSS Goals and Benefits

Key Ingredients for success

Quantifying Savings and Benefits

The DFSS Scorecard

Keeping Score using the DFSS Scorecard

Scorecard Elements and Construction: Parts, Process, Performance and Software

Methods for Computing DPU

Hands-on practice completing a DFSS Scorecard using DFSS Software

Identify: The DFSS Project and Team

DFSS projects and studies

Key elements of the business case

Initiating and Scoping the project

Project charters

The DFSS team

Stakeholder analysis

Identify: The Voice of the Customer (VOC)

The Identify phase of IDOV

Kano's Model

Determining Customer Wants and Needs

Sampling Methods

Identifying Critical to Customer Requirements

Prioritizing Customer Requirements

Introduction to Quality Function Deployment (QFD) and the House of Quality

Hands-on Practice Completing House of Quality #1 to identify Measurable CTCs (critical to customer measures)

Design: Concept Generation and Selection, Product Design, and Requirements Flowdown

The Design phase of IDOV

Assigning Specs and Formulating Design Concepts

FAST diagrams

Overview of Triz and Axiomatic Design

Comparing Alternate Design Concepts using Pugh Concept Selection

Risk Analysis and Management

Building House of Quality #2

Design and Optimize: Transfer Functions and Expected Value Analysis (EVA)

Importance of Transfer Functions for IDOV

Methods for Obtaining Transfer Functions

Meaning of expected value

Expected Value Analysis (EVA) for Quantifying the Distribution of the Output

Comparing Methods and Strategies for EVA:

Root Sum Square (RSS)

Monte Carlo Simulation

Using DFSS software for EVA Analysis

Determining distribution of inputs

Working with Normal and Non-Normal Input and Output Distributions

Optimize: Robust Design


Noise factors and P-diagrams

Robust Design: Finding Optimal Mean Settings for the Inputs to Minimize Variation in an Output

Methods for Robust Design

Computer Based Robust Design (Parameter Design) using DFSS software

Robust design examples and exercises

Optimize: Tolerance Allocation Quantifying the Sensitivity of the Output DPM to Changes in the Input Variable's Standard Deviation

Tolerance Allocation Examples and Exercises

Setting Tolerances

Methods to Reduce the Standard Deviation of Inputs

Design for X-ability and Scorecard Updates

DFX Concepts - beyond just designing for performance

DFX principles and examples

Introduction to Design for Reliability (DFR):

Designing with Reliability in Mind

Common life data distributions and analysis

Mistake Proofing and Error Proofing

Capability prediction

Design scorecard updating and analysis

Validate: Sensitivity Analysis

Sensitivity Analysis

Quantifying the impact of mean and standard deviation shifts in design inputs

Validate: The Achievement of Breakthrough Performance

Developing prototypes, test cases and pilots

Introduction to high throughput testing for validating performance

Performing gap analysis if results don't confirm

DFSS Case Studies and Examples

Design Exercise: Applying the IDOV Methodology

Hands-on practice with the IDOV process

Teams Design a Product to Meet the Customer Needs, using the IDOV process; Teams optimize their design using the IDOV tools and ultimately build and test their designs to validate performance

Course Materials

Materials provided with the course:

Student participant guide (workbook)

Textbooks: Understanding Industrial Designed Experiments

Basic Statistics: Tools for Continuous Improvement

Design for Six Sigma: The Tool Guide for Practitioners

Software included with the course:

SPC XL, DOE Pro, Quantum XL

Attendees are required to bring a laptop with them to this course.

Course Details

Course start Thu 1st January 2015
Course end Thu 31st December 2015
Individual price
Extra Information To secure your seat please submit a Registration Form. If you are waiting for financial/supervisor approval you are welcome to reserve a seat without commitment. Please note that the course fee is ex GST. We thank you for your interest and look forward to hearing from you.
Course location
Please register your interest in this course by contacting Babcock on +61 (0)8 8440 9507

Register Here!

Registering for one of our courses is easy! Simply fill out one of the below Course Registration Forms and return via email to training@babcock.com.au

Course Registration Form - Individual Attendees

Course Registration Form - Multiple Attendees

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GST Terms

All prices shown are Exclusive of GST. GST of 10% will be added to all invoices