Commercializing Great Products with Design for Six Sigma

107 Chapter 11 Estimating Financial Value 109 Calculating the Project Value 109 How to Handle Fixed Costs 110 Examining the Project Returns 115 Chapter 12 Product Positioning 123 The Market Perceived Quality Profile 123 Product Positioning Maps 129 Section III The Voice of the Customer 131Chapter 13 Concept Development 133 The Concept Development Process 133 Concept Development Applications 135 Advantages of the Concept Development Process 135 Chapter 14 Developing the Interview Guide 139 Developing a Purpose Statement 139 Identifying and Listing Five to Ten Bullet-Point Interview Objectives 140 Developing a Customer Selection Matrix 141 Creating the Interview Guide Questions 143 Chapter 15 Conducting Customer Interviews 151 Preparing for the Interviews 151 Interview Team Roles 152 Conducting the Interview 153 Debriefing the Interview 155 Good Project Management of the Interview Process 155 Practice, Practice, Practice 156 Chapter 16 KJ Analysis 157 An Overview of the KJ Process 158 The Image KJ 158 The Requirements KJ 168 The Next Steps 178 Chapter 17 Relative Importance Survey 179 Designing and Conducting the Survey 179 Analyzing the Survey Results 183 Identifying Requirements in Kano Terms 185 Chapter 18 Ideation 187 The Ideation Process 187 Ideation in the Candy Wrapper Film Case Study 190 Chapter 19 Pugh Concept Selection 193 The Pugh Concept Selection Process 194 Pugh Concept Selection in the Candy Wrapper Film Case Study 198 Chapter 20 QFD 199 The Value of QFD 199 Executing the QFD 201 The QFD Flowdown 206 QFD across the Value Chain 209 Some Final Thoughts 215 Chapter 21 TRIZ 217 Technical Contradictions 218 The TRIZ Methodology 218 Some Final Thoughts on TRIZ 229 Chapter 22 Critical Parameter Management 231 Documenting Critical Information from the QFD 232 The Critical Parameter Scorecard 232 The Benefits of Using Critical Parameter Scorecards 236 Section IV Product/Process Development 239Chapter 23 Process Mapping 241 Types and Uses of Process Maps 241 The Process Variables Map 241 The "As-Is/Can-Be" Process Map 247 Some Final Thoughts on Process Mapping 249 Chapter 24 Cause and Effects Matrix 251 Comparing C&E Matrix and QFD3 251 Developing the C&E Matrix 252 Using the C&E Matrix Output 257 Chapter 25 Failure Modes and Effects Analysis 263 Two Types of FMEA in New Product Development 263 The Design FMEA 264 The Process Design FMEA and the Process Manufacturing FMEA 271 Chapter 26 Statistical Analysis Tools Overview 275 Variation in Product and Process Development 275 Some Basic Statistics 279 Graphical Analysis Techniques 282 Numerical Descriptive Statistics 301 A Look Ahead 303 Chapter 27 Measurement Systems Analysis 307 Measurement System Error 307 The Impact of Measurement Error in Development 308 Assessing Measurement System Usefulness 309 Conducting a Measurement System Study 316 Long-Term Measurement System Assessments 322 Chapter 28 Process Capability 323 Using the Normal Distribution Curve to Estimate Waste 323 Short-Term Process Capability Analysis 325 Long-Term Process Variation: The Shift 326 Designing for Six Sigma Performance 329 Revisiting the Cp Statistic 330 The Cpk Statistic 332 Long-Term Process Capability Analysis 335 Interpreting the Capability Indices 336 Capability Analysis in Minitab 337 Ensuring Measurement System Adequacy 341 Process Capability for Attribute Data 343 The Importance of Process Capability 344 Chapter 29 Tools for Data Analysis 347 General Methods of Data Analysis 347 Hypothesis Testing 348 Sample Size Calculation 350 Comparing a Process Mean to a Target Value 352 Comparing Means and Standard Deviations from Two Film Samples 359 Comparing Two Variances 364 Comparing Two Means: 2-Sample t-test 364 Comparing 2 Medians: The Mann-Whitney Test 367 Comparing Two Means: Paired Comparisons 367 Assessing Means and Standard Deviations: Con*dence Interval 371 Comparing Means and Standard Deviations from More Than Two Samples 374 Comparing Variance 377 Comparing Means: One-Way ANOVA 379 Comparing Medians: Kruskal-Wallis Test 384 Data Comparison Tools Summary 385 Correlation Analysis 385 Regression Analysis for a Single Input Variable 388 Multiple Regression Analysis 394 Correlation and Regression Analysis Summary 400 References 400 Chapter 30 Design of Experiments 401 Full Factorial Designs 401 Fractional Factorial Designs 415 Response Surface Designs 424 Choosing an Experimental Design 430 References 432 Chapter 31 Robust Design 433 Quantifying Robust Design Performance 433 The Taguchi Approach to Robust Design 435 Robust Design Example 438 Alternative Approaches to Robust Design 442 Dealing with Variation 447 Chapter 32 Mixture Experiments 449 Mixture Equations 449 Mixture Designs 451 Creating Mixture Designs in Minitab 451 Analyzing a Mixture Design Experiment 455 Response Surface Study for a Mixture Investigation 458 Choosing a Mixture Design 466 References 468 Chapter 33 Seeking an Optimal Solution 469 The Multiple Response Optimization Process 470 Three-Response Optimization 477 Monte Carlo Simulation in Optimization 481 Multiple Response Optimization Final Thoughts 488 Chapter 34 Design for Reliability 491 A Roadmap for Reliability 491 Design for Reliability 493 Identifying Reliability Requirements: VOC 493 Reliability Expectations and the Kano Model 494 Customer Reliability Expectations 495 Typical Reliability Metrics 495 The Hazard Function 498 Types of Reliability Tests 503 Reliability and Failure Modes and Effects Analysis 506 Reliability Functions and Mathematical Models 508 Types of Distributions and the Hazard Function 511 Reliability Modeling Using Minitab Software 512 The Implications of Product Reliability on Warranty Costs 516 Chapter 35 Statistical Tolerancing 519 Worst Case Analysis 520 Root Sum of Squares Analysis 521 Six Sigma Tolerance Analysis 525 Chapter 36 Production Scale-up 541 Confirming the Product 542 Design for Manufacturability Assessment 550 Scaling up the Product 553 Chapter 37 Control Plans 559 Developing a Control Plan 560 The Final Control Plan Package 572 Section V Product Launch and Project Post-Mortem Analysis 575Chapter 38 Product Launch and Project Post-Mortem Analysis 577 Product Launch Planning 577 Project Post-Mortem Analysis 583 Conclusions 588 Appendix A Glossary 589Appendix B Abbreviations 599Index 601