Executive Education
INDIVIDUALS Courses
Certificates

About Your Visit Fluno Center
About Madison
About Campus
EMPLOYERS Custom Programs
Custom Development Process
Success Stories
Clients
Information Request
View Cart (0)
Cart Preview
    Design for Lean Six Sigma

    Design and launch a new process, product or service correctly the first time

    Please note that Business Process Improvement Using Lean Six Sigma and Performance Metrics is a prerequisite course, and you must complete it before taking Design For Lean Six Sigma.

    When designing new products, services, software, Web portals, or anything else, it is crucial to achieve customer delight at the lowest cost and shortest time to market.

    The Design for Lean Six Sigma set of approaches can dramatically improve new product and service success rates, reduce costly redesigns and software patches and eliminate service headaches after the launch.

    This workshop will cover the entire set of standard Design for Lean Six Sigma approaches and show you how to apply them in your organization. As an added bonus, you will learn how the most innovative companies in the world generate breakthrough new product ideas at the “fuzzy front end” of the product and service development process. It is this combination of strategic innovation and Design for Lean Six Sigma that sets world-class companies apart from the rest.

    Bring your new product, service, software or other new challenge to the workshop and apply the techniques right in the session. Leave with a roadmap on how to introduce Design for Lean Six Sigma into your business, and successfully facilitate your team through the process.

    You’ll learn to:

    • Utilize the benefits of Design for Lean Six Sigma
    • Reduce development costs of new products,
      services, software, etc.
    • Increase customer delight, revenue and profit
    • Shorten development times and time-to-market
    • Leverage your design resources by avoiding fire fighting
    • Lower manufacturing, operating and service costs
    • Lessen early-life failures and lower warranty costs

    Who should attend:

    • New product engineers or managers
    • Quality managers
    • Operations managers
    • Business systems analysts
    • Six Sigma practitioners

    Introduction to Design for Lean Six Sigma (DFLSS)

  • Why it is needed and the benefits of applying it
  • How it differs from the DMAIC process of Lean Six Sigma
  • Overview of the five steps in Design for Lean Six Sigma: Define, Measure, Analyze, Design and Verify (DMADV)
  • Variations on the approach at GE and other companies: IDDOV, DMEDI, and others
  • Pitfalls and preventatives in applying DFLSS

    • New Product and Service Innovation

    • Toyota's famed New Product Development System and Culture
    • Strategic Innovation at GE, Proctor & Gamble, and many other top companies
    • Generating Breakthrough New Product and Service ideas
    • Managing the "Fuzzy Front End" of the product development process
    • Best Practices in New Product Development: Stage-Gates, Concurrent Engineering, Design for Manufacturability, etc.
    • Criteria for selecting new product and service ideas

    Five-Step DMADV Process:

    • Learn and apply all of the techniques in each of the steps of DMADV
    • Combine creativity with rigorous analysis and design methods
    • Organizing for DFLSS
    • Team formation, selection and sponsorship

    Define:

    • Develop the business case and opportunity statement
    • Scope and charter the project
    • Project planning, role contracting, and PERT and GANTT Charts
    • Voice of the Customer (external and internal) analysis
    • Market segmentation methods
    • Sources of unmet and latent customer needs
    • Marketing research methods:
    • Contextual Inquiry
    • "Day in the Life" analysis
    • One-on-one in-depth interviews
    • Focus Group
    • Telephone surveys
    • Mail surveys
    • Customer needs analysis techniques:
    • Factor analysis and trees
    • Perceptual mapping
    • Conjoint analysis
    • Other multivariate techniques
    • Risk analysis
    • Tollgate reviews

    Measure:

    • Quantify CTQs for customer, business, technical, service, and regulatory design inputs
    • Kano model for identifying "delighters"
    • Kansei Engineering
    • Quality Function Deployment (QFD)—Cascaded downward
    • Product
    • Design
    • Manufacturing Process
    • Operational Processes
    • Benchmarking and Reverse Engineering
    • Operational Definitions of each metric
    • Translating Brand Promise into design specifications
    • Using DFLSS on New Service Processes
    • Multi-stage product and service plans

    Analyze:

    • Map CTQs to design features and functions
    • Critical to Safety (CTS) and other metrics
    • Customer Demand Models
    • TRIZ
    • Pugh Matrix
    • Numerous creativity techniques
    • Develop and investigate high-level conceptual designs
    • Choose best concept
    • Document the design options
    • Failure Modes and Effects Analysis
    • Error Mode and Error Analysis
    • Product Design Creativity techniques
    • Robust design methods

    Design:

    • Develop high-level and detailed designs of the product, service or process
    • Rapid Prototyping
    • Simulation approaches
    • Tolerance optimization
    • Design Scorecard
    • Design of Experiments
    • Response Surface Methodology
    • Hypothesis testing
    • Reliability testing
    • Process Capability Analysis
    • Design for Manufacturability, Lean, Service, Sales, etc.

    Verify:

    • Confirm the outputs of the design and development process
    • Validate fitness for use
    • Error and mistake proofing
    • Standardization methods
    • Introduction to manufacturing
    • New Product and Service Scorecards
    • Pilot testing
    • Alpha, Beta and Market Testing
    • Project Documentation
    • Track your new product and service successes
    • Post-mortem reviews and continuous improvement

    Workshop Conclusion

    • Tailoring DFLSS to your organization
    • Change Leadership
    • Personal Planning

    James Bandrowski

    Jim Bandrowski is president of Strategic Action Associates in Danville, Calif., and author of Corporate Imagination–Plus: Five Steps to Translating Innovative Strategies into Action (Simon & Schuster). Industry Week stated: “James Bandrowski's system emphasizes action that helps companies beat their competition.” In May 2009, he coauthored his second book, Discover Your Inner Strength, with Stephen Covey, Ken Blanchard, and Brian Tracy. He helps clients achieve remarkable measurable results in health care, high tech, oil, consumer products and services, industrial equipment, business services, and government and nonprofit organizations. Clients include GE, Disney, Merck, AT&T, Hewlett-Packard, Boeing, Kodak, TRW, Electronic Arts, Mazda, Suntory, Chevron, Exxon, Saudi Aramco, Safeway, Century 21, First National Bank, MITRE, Vlasic Pickles, Kaiser Permanente, HealthNet, the U.S. Navy, and various cities.