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DFSSzed and DMAIConfused

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  • #51176

    Arora
    Participant

    I’m in a new situation.  Your thoughts would be appreciated.
    I am a DMAIC Black Belt with 70 projects either personally completed or mentored.  I am expecting an offer soon to work as a DFSS Black Belt.  I have no DFSS training.
    How far am I behind?  Is there a DFSS BB certification, or is is a small subset of the MBB body of work?
    Thanks, and go easy on me.  I really did look around before coming here.
    KJX
     

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    #177009

    Don Strayer
    Participant

    Search this site for DMEDI (Define, Measure, Explore, Develop, Implement).  This is the most common approach to DFSS, although there are others.  The big difference is that you do not begin with an existing process.  Most of what you know from DMAIC still applies but with a different focus.

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    #177020

    Szentannai
    Member

    Hi Kris,
    in a nutshell, in DFSS you need to optimize something that does not yet exist. This means that you have a strong emphasis on modelling (mathematical or other) and you apply many of the DMAIC tools on these models.
    Of course given the nature of the models, you need a lot of special tools as well.
     
    Regards
    Sandor

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    #177026

    Stevo
    Member

    Kris,
     
    As with most of what we do, there is a huge difference between average and expert.  IMO – If you understand the central philosophies behind Six Sigma, you are not that far away.
     
    Understand the QFD process well and read any DFSS book and you can get by until you have the time and experience to become more of an expert.
     
    Stevo

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    #177038

    Arora
    Participant

    Gentle Protectors of the Faith (and anyone else who wants to chime in),
    After searching the net and 5 years of forum posts, I see no one answering “yes” to the question:
    Is there any precedence for a DFSS certification?
    Good.  I’ll start handing them out unless someone can give me a reason not to.
    KJX

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    #177045

    Ken Feldman
    Participant

    As with most certifications, there is no true governing body deciding content, requirements, etc.  A quick Google search does reveal that there are some folks out there awarding DFSS Certification.  One of my clients recently awarded one of my BB students a DFSS GB certification.  So, they are out there.  If you want to model your own, then check out what some of the others are doing….I saw one from SBTI for whatever it is worth.  So the answer is “YES”.

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    #177046

    Mikel
    Member

    Please don’t just hand them out. Do it the old fashioned way and
    make people earn them with knowledge applied to projects have
    achieved significant results.

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    #177047

    Arora
    Participant

    As someone who protects the integrity of my own certification, I will exact proof that anyone with a DFSS cert issued by me will be able to apply know and apply at least: 

    DMAIC Tools and project work sufficient to achieve SSBB status
    the three most recognized roadmaps DMADV, ADDIE, and DMEDI, and the situations where each might offer advantage
    project charters, stakeholder analysis
    DOE
    risk analysis
    DFMEA, EFMEA
    PERT and Gantt charting 
    the cascading QFD path, Pugh matrix
    Cause and Effects diagrams and matrices
    5-Why and PDCA
    and pass an exam that shows that they can pick which to use and interpret results of statistical analysis.
    Does this sound like a good start, y’all?
    What should be added?
    KJX
     
     

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    #177049

    Mikel
    Member

    Sounds right but I would add a successful design project to the
    criteria. Success in my mind means -On target for schedule, budget and the new product/process was at
    the target cost, cycle time, and quality. And those target had better be
    more aggressive than the historical achievements.I think you are on the right path.

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    #177050

    MBBinWI
    Participant

    I’ve been practicing what has become known as DfSS for over 15 years.  I didn’t come up through the DMAIC SS ranks, rather started as an engineer trying to make sure that the products that I developed were free from defects/waste from initial production. 
    1. I’ve never heard of ADDIE.
    2. Since our principal focus is in creating products, and we already have a phase gate process, we don’t use any acronym for our DfSS methods – they are woven into the overall phase gate methods.  I would expect that most applications creating products are similar.
    3. You do not include a design scorecard (sometimes called a CTQ scorecard or CPM scorecard).  The fundamentals of the scorecard are that the critical customer requirements are listed, the acceptance criteria (spec levels) are established, then data is gathered to determine the capability (z-score, Cpk, PPM, etc.) for each.  The rest of the tools that you identify are used to improve these scores.  As Knute Rockne once said, “if you’re not keeping score, you’re just practicing.”  If you don’t have a design scorecard, you’re not doing DfSS.

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    #177051

    MBBinWI
    Participant

    With all due respect, Don, I must disagree with the comment that DMEDI is the most common approach (never heard of it prior to this post), nor do I think that for most DfSS practitioners developing products in a phase-gate system, that any of the common acronyms (DMADV is the most common – but every consultant out there seems to have their own twist) are even necessary.  Follow your product development process and apply the right tool to develop the right information.  The most critical item is a design scorecard (also called CTQ or CPM scorecard).  This identifies the critical customer requirements, the acceptance criteria (spec limits) and data on performance to determine design capability (z-score, Cpk, PPM, whichever flavor you like). 
    Yes, all of the tools that you learned in DMAIC have utility in DfSS, but in DMAIC you are just reducing variation.  In DfSS, you usually have to develop the transfer function, and then tune the variables to desensitize them to uncontrolled sources of variation to achieve an adequate level of robustness.  In order to do this, you will need to anticipate those sources (FMEA, C&E, etc.) and then you will most likely simulate the system in some fashion to inject the variation of the X’s to see how that affects the Y(s).  Monte Carlo is a tremendous tool for doing this, and is usually not part of a DMAIC tool kit (although I cannot understand why not).  Get familiar with a MC simulation tool that works in your context (I use CrystalBall, but there are others that may be better for your situation).
    I applaud you moving into the DfSS world.  You will need to have a shift in thinking from trying to gather data from existing processes, to anticipating and predicting possible sources, experimenting to characterize the system (develop the transfer function), and simulate as a means to understand the impact of variation and then reduce it by tuning the control factors in the design.

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    #177052

    MBBinWI
    Participant

    Kris:  What do you mean by “precedence”?  If you are looking for criteria, I can share what we use.

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    #177053

    Mikel
    Member

    Amen on all the dumb axx acronyms that are out there for DFSS. Best comment I’ve seen on this site in months.

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    #177063

    JDI
    Participant

    SixSigma* pronunciation guide:DMAIC – “dee-MAY-ik”DFSS – “DOO-fuss”Example: “This doesn’t look like a DMAIC project, it looks like a DFSS project”*Or some combination of “leanSomething, “eSomething”, “iSomething”, “MindProtestingSomething”, etc. ; I don’t know what’s trendy today.

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    #177091

    Arora
    Participant

    Precedence meaning has anyone gone before me (well, obviously) and was their approach to the DFSS Certification.
    So, yes, please share your methodology for assessing and blessing aspiring DSS candidates.
    Kris

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    #177093

    anon
    Participant

    Kris, first they must learn proper grammar and acquire typing skills since communication is paramount. So do that first then come back for the more technical issues.

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    #177119

    Mike Carnell
    Participant

    Kris,
    We don’t have a certification for DFSS. There is additional training done for people who need that specific knowledge and application.
    Good luck.

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    #177159

    MBBinWI
    Participant

    What’s your problem?  If you were trying to be funny, you missed.

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    #177160

    MBBinWI
    Participant

    Stan, since it seems that you monitor these hallways, I’d be interested in your take on this.
    Here is what we do.  The overall DfSS methodology is segmented into 4 principal buckets: VOC, Concept Engineering, Robust Optimization, and Reliability/Validation.  Each of these buckets constitutes a Green Belt level and is focused on a functional group in the organization which has principal responsibility for the activities within that bucket (i.e., marketing for VOC, system engineering for concept engineering, design and manufacturing engineering for robust optimization, and reliability/quality for the reliability/validation/control plans portion).
    Most of the product development organization will never progress past the GB level as they typically remain within their functional domain.  To get certification at the GB level, you would perform the activities within that bucket to accomplish the major deliverable for that bucket (a product specification for VOC as an example, or a design concept as another).  Two iterations are necessary, as well as an evaluation of overall competency.  Since DfSS is principally cost avoidance, there is no cost savings requirement.
    For those wanting to be more of a DfSS specialist (read that BB), they are required to get a GB certification in one of those original buckets, get trained in the others, and complete two projects (typically as a project team leader or project manager) that covers the expanse of the entire product development process.  We give them more detailed statistical training and do a comprehensive assessment.  MBB’s are those who have achieved BB plus worked other projects, mentored project teams (with or without GB or BB) and have training capability.

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    #177161

    MBBinWI
    Participant

    Oh, by the way – the GB certification is not GB DfSS, rather GB in VOC, GB in Concept Engineering, GB in Robust Optimization, GB in Reliability/Validation. 
    The expanse of DfSS seems to make it non-sensical to talk about a GB in the overall process of DfSS.

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    #183271

    MBBinWI
    Participant

    Kris:  Just following up – how’s your DfSS implementation going?

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