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Small Library for Six Sigma / DFSS

Quality Approaches and Models
Six Sigma – A vision of quality which equates with only 3.4 defects per million opportunities for each product or service transaction. Strives for perfection.
DMAIC – (Define, Measure, Analyze, Improve and Control) is a process for continued improvement. It is systematic, scientific and fact based. This closed-loop process eliminates unproductive steps, often focuses on new measurements, and applies technology for improvement.
DFSS – (Design for Six Sigma) is a systematic methodology utilizing tools, training and measurements to enable us to design products and processes that meet customer expectations and can be produced at Six Sigma quality levels.
IDOV – (Identify, Design, Optimize, Validate) is a process for continued improvement applied in DFSS methodology. It is systematic, scientific and fact based. This closed-loop process eliminates unproductive steps, often focuses on changes from the design level, and applies technology for design improvement, enables us to design products/processes that will meet or exceed the customer’s expectations.

Quality Tools
Control Chart – Monitors variance in a process over time and alerts the business to unexpected variance which may cause defects.
Defect Measurement – Accounting for the number or frequency of defects that cause lapses in product or service quality.
FMEA – is a systematic approach used to examine potential failures and prevent their occurrence. It enhances an engineer’s ability to predict problems and provides a system of ranking, or prioritization, so the most likely failure modes can be addressed.
Pareto Diagram – Focuses on efforts or the problems that have the greatest potential for improvement by showing relative frequency and/or size in a descending bar graph. Based on the proven Pareto principle: 20% of the sources cause 80% of any problems.
Process Mapping – Illustrated description of how things get done, which enables participants to visualize an entire process and identify areas of strength and weaknesses. It helps reduce cycle time and defects while recognizing the value of individual contributions.
Root Cause Analysis – Study of original reason for nonconformance with a process. When the root cause is removed or corrected, the nonconformance will be eliminated.
Statistical Process Control – The application of statistical methods to analyze data, study and monitor process capability and performance.
Tree Diagram – Graphically shows any broad goal broken into different levels of detailed actions. It encourages team members to expand their thinking when creating solutions.

Quality Terms
Baseline – The average long-term defect level of a process when all input variables in the process are running in an unconstrained fashion.
Benchmark – The defect level of the process deemed by comparison to be the best process possible.
Black Belt – Leaders of team responsible for measuring, analyzing, improving and controlling key processes that influence customer satisfaction and/or productivity growth. Black Belts are full-time positions.
Control – The state of stability, normal variation and predictability. Process of regulating and guiding operations and processes using quantitative data.
CTX – Critical to X characteristics which is critical to customer satisfaction, such as Quality / Cost / Delivery, etc. Element of a process or practice which has a direct impact on its perceived characteristics.
Customer Needs, Expectations – Needs, as defined by customers, which meet their basic requirements and standards.
Defects – Sources of customer irritation. Defects are costly to both customers and to manufacturers or service providers. Eliminating defects provides cost benefits.
Entitlement – The best-case short-term defect level of a process when all input variables in the process are centered and in-control.
Green Belt – Similar to Black Belt but not a full-time position.
KPIV – Key Process Input Variables
KPOV – Key Process Output Variables
Master Black Belt – First and foremost teachers. They also review and mentor Black Belts. Selection criteria for Master Black Belts are quantitative skills and the ability to teach and mentor. Master Black Belts are full-time positions.
Variance – A change in a process or business practice that may alter its expected outcome.
VOC – Voice Of the Customer is used to describe customers’ needs and their perceptions of the product or service.
Terms for FMEA
Causes – This is the list of causes and/or potential causes of the failure mode.
Current Controls – All means of detecting the failure before product reaches the end user are listed under current controls.
Effect – Assuming a failure does occur, describe the effects. List separately each main effect on both a downstream operation and the end user.
Effectiveness – The effectiveness of each current control method is rated on a provided scale from 1 to 10. A 10 implies the control will not detect the presence of a failure; a 1 suggests detection is nearly certain.
Failure Mode – Any way in which a process could could fail to meet some measurable expectation.
Occurrence – This is a ranking, on a scale provided, of the likelihood of the failure occurring. 10 represents near certainty; 1 represents 6 sigma. In the case of a Six Sigma project, occurrence is generally derived from defect data.
Severity – Using a scale provided, rate the seriousness of the effect. 10 represents worst case, 1 represents least severe.
Terms for DFSS

Identify – to translate customer's requirements into CTX characteristics for the product or service

Design – to determine and develop input variables (KPIVs) that are critical to design features or concepts (KPOVs) necessary to meet the customers' expectations.

Optimize – to develop and optimize the relevant tolerance for the respective input variables.

Validate – to ascertain the reliability product or service design, and to identify the critical inputs that need to monitored for process stability

PNC – Probability of Non-Conformance, is calculated from 1-yield. For the normal data, it is automatically calculated from the input mean, sigma and spec limits, but for non-normal or attribute data, PNC should be directly input to the column.

Gage %P/P – (Precision to Process Ratio) also known as Precision to Total Variation ratio, is calculated by 100*STD-gage/STD-total, we should input the number just below (%SV) in MiniTAB GR&R output

Maturity Level – the number of level used in DFSS methodology to measure what is the maturity status for the activity. Detail definitions, refer to the matrix in Appendix.