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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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Breakthrough Performance using Design for Six Sigma

Great systems don’t come by accident - they are the result of a systems engineering process that seeks the right solution for a customer’s need. How quickly and efficiently this answer is reached however often varies, for many reasons. If you work in an environment where cost, schedule and capability all count, then this course is for you.

The Design For Six Sigma (DFSS) course provides participants with a range of tools and techniques to avoid development/service problems at the outset – where prevention is always better than the cure. For clarity, this isn’t traditional six sigma, which focuses on process efficiency. DFSS  focuses on the early stage of development – where the cost of rectification and change is small, in comparison with later on in the development lifecycle.

This 1 week hands-on workshop with Dr Mark Kiemele teaches the Identify, Design, Optimize, and Validate (IDOV) strategy for delivering better systems and services to customers faster and at a lower cost. The course uses the “Keep It Simple Statistically” (KISS) approach that includes many in-class examples and exercises. Participants have ample opportunity to practice what is taught to ensure they have a practical, working knowledge of the IDOV tools and methodology.

The proven and powerful DFSS methodology can be used for both initial design as well as re-design efforts, and provides a way to implement the Six Sigma methodology as early in the product or service life cycle as possible. Participants will learn how to “design in” quality when costs are the lowest and create innovative products and services which exhibit outstanding performance right from the start.

Participants will learn the details necessary to identify the voice of the customer, design products and processes which satisfy the customer’s requirements, optimize products and processes to maximize performance and test and validate designs to ensure capability. During the course, participants complete a team-based hands-on design where they will design, build and test a product using the IDOV strategy.

This is not a theoretical course - participants leave the course with a range of practical skills that can be applied directly in their workplace.

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/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

Understanding how input means affect output performance

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

Team 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 to this course)

Course Details

Course start Mon 13th November 2017
Course end Fri 17th November 2017
Individual price $4,400.00
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 Adelaide (Mawson Lakes)
Please register your interest in this course by contacting Babcock on +61 (0)8 8440 9507

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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

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Course Calendar

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