DFSS (Design for Six Sigma) project or SSBB project?

C

capnkrk

#1
Hey folks-

I'm an ASQ CSSGB, currently taking a BB course through a tech school to ultimately prepare for the ASQ SSBB exam.

I need a project to sit for the exam. Here's my idea:

We are getting a new piece of equipmenty in house that will have an entirely different work flow and changeover process. Getting these processes right is critical to our growth and success. My instructor feels that this is a DFSS situation, and wouldn't qualify as a BB project.

However, we have developed standard work and designed a new work flow. Once we get the equipment in house we'll test our designs and improve upon them. Why wouldn't that work as a BB project?

As a rhetorical question, why doesn't DFSS qualify as a black belt project? It's critical, and can potentially save huge $.

thoughts???
 
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Miner

Forum Moderator
Staff member
Admin
#2
It sounds like it is a situation that could benefit from both approachs. The key question that you need to ask is whether it will provide you with the opportunity that you need to demonstrate mastery of the LSS BoK for your certification. If it does provide that opportunity then go for it. Just make sure that you scope your project accordingly.
 

Bev D

Heretical Statistician
Staff member
Super Moderator
#3
In general the difference between DFSS and 'regular' Six Sigma is that regualr six sigma focuses on the entier problem solving process while DFSS concentrates on the development process. Many of the same tools are used, but not all and not in the same sequence. DFSS should take a much longer time than problem Solving Six Sigma, simply becasue hte design and development process takes many months and/or years depending on the product. *I* don't distinguish between the two for 'certification', but many do.

The situation you describe is neither. It sounds more like you have done a little LEAN work (standard work and work flow).

If this new equipment/process produces defects then you will have a six sigma project...

Unfortunately as the whole 'six sigma' thing has become commodotized and watered down and manipulated for profit, these 3 things have become an unrecognizable amorphous blob for too many 'teachers' and consultants...
 
C

capnkrk

#4
In general the difference between DFSS and 'regular' Six Sigma is that regualr six sigma focuses on the entier problem solving process while DFSS concentrates on the development process. Many of the same tools are used, but not all and not in the same sequence. DFSS should take a much longer time than problem Solving Six Sigma, simply becasue hte design and development process takes many months and/or years depending on the product. *I* don't distinguish between the two for 'certification', but many do.

The situation you describe is neither. It sounds more like you have done a little LEAN work (standard work and work flow).

If this new equipment/process produces defects then you will have a six sigma project...

Unfortunately as the whole 'six sigma' thing has become commodotized and watered down and manipulated for profit, these 3 things have become an unrecognizable amorphous blob for too many 'teachers' and consultants...
Thanks for the perspective. Just so I am clear: the reduction of setup time is considered a lean initiative, not six sigma?

I have read about many 'six sigma' projects addressing on time deliveries and similar metrics, what makes mine different?
 
K

KathySmith

#5
Unless it's changed:

1) Six Sigma (DFSS) is more focused on a new process were none existed before.

2) BB is attacking a problem to a more established process. A common student mistake is to try to fix more than one problem in a BB project. Keep it simple.

Then there's Lean Six Sigma. Many of the Lean and Six Sigma tools are complicated and overlap the methodologies. It can be confusing everyone even the hardcore. But remember new or existing.
 

Stijloor

Staff member
Super Moderator
#6
Unless it's changed:

1) Six Sigma (DFSS) is more focused on a new process were none existed before.

2) BB is attacking a problem to a more established process. A common student mistake is to try to fix more than one problem in a BB project. Keep it simple.

Then there's Lean Six Sigma. Many of the Lean and Six Sigma tools are complicated and overlap the methodologies. It can be confusing everyone even the hardcore. But remember new or existing.
I found it all very confusing, so I stick with "Continuous Improvement."
Including the basic seven quality tools. :cool:
 

Bev D

Heretical Statistician
Staff member
Super Moderator
#7
Thanks for the perspective. Just so I am clear: the reduction of setup time is considered a lean initiative, not six sigma?

I have read about many 'six sigma' projects addressing on time deliveries and similar metrics, what makes mine different?
typically reducing set-up time a lean project.
the critical difference in all of these is what 'tools' are used.
it is silly to use statistics to reduce setup time. (other than perhaps a control chart on set-up times to demonstrate before and after)

I know that some companies and consultants blur the tools across lean and six sigma but this is usually a sign of ignorance concerning either lean and/or six sigma. Too many people over-use the t-test, ANOVA, Cpk stuff for Lean when it is just a total misapplication of these tools and absolutely non-value-add processing. This usually comes form 'six sigma' people who have no clue what Lean is.

There are some lean improvements that require 'six sigma' tools (such as DoE and techncial problem solving) to eliminate a defect in order to eliminate a bottleneck or improve cycle time, or solve a late delivery problem, etc. I've also used six sigma tools (MSA and correlation) to prove that certain inspections were no longer needed or were ineffective in order to remove the inspection (non-value-add processing). so there is some overlap of the two methods, which is why they are synergistic and we tend to use the phrase Lean Six Sigma or better yet: Operational Excellence.
 
C

capnkrk

#8
typically reducing set-up time a lean project.

Thanks Bev. Interesting that ASQ itself lists "reduced manufacturing machine setup time" as a qualifying Six Sigma project for sitting for the BB exam. I agree it's silly to shoe horn in analyses that are unnecessary for the project.
 
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Bev D

Heretical Statistician
Staff member
Super Moderator
#9
Well, ASQ has watered down the criteria even requiring only 1 project instead of 2. They were 'Johnny come lately' in the six sigma fad...

I can see how a project requiring machine redesign in order to reduce setup time would qualify.
 
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