Advanced Material Technology

Six Sigma Material Selection

Sham Tadwalkar
Material Selection – Six Sigma Process

12 step to six sigma for robust product development process

Traditional product development process

Material Selection – Six Sigma Process
Material Selection – Six Sigma Process
Material Selection – Six Sigma Process
Material Selection – Six Sigma Process
Material Selection – Six Sigma Process

Six Sigma is a highly disciplined process that helps us focus on developing and
delivering near-perfect products and services. Why ”Sigma“? The word is a
statistical term that measures how far a given process deviates from perfection.
The central idea behind Six Sigma is that if you can measure how many “defects”
you have in a process, you can systematically figure out how to eliminate them
and get as close to “zero defects” as possible.
There are three key elements of quality: customer, process and employee.
Everything we do to remain a world-class quality company focuses on these three essential elements.

Delighting Customers

Customers are the center of business process: They define quality. They expect performance, reliability, competitive prices, on-time
delivery, service, clear and correct transaction processing and more. In every attribute that influences customer perception, we know
that just being good is not enough

Quality requires us to look at our business from the customer’s perspective, not ours
All employees are trained in the strategy, statistical tools and techniques of Six Sigma quality.
Training courses are offered at various levels:
Quality Overview Seminars: basic Six Sigma awareness.
Team Training: basic tool introduction to equip employees to participate on Six Sigma teams.
Master Black Belt, Black Belt and Green Belt Training: in-depth quality training that includes high-level statistical tools, basic quality control tools, Change Acceleration
Process and Flow technology tools.
Design for Six Sigma (DFSS) Training: prepares teams for the use of statistical tools to design it right the first time.
Quality is the responsibility of every employee.
Material Selection – Six Sigma Process
Material Selection – Six Sigma Process
Material Selection – Six Sigma Process
Six Sigma brings following improvements in TQM –

1. Integration of quality tools and systems

2. Improved processes, training and competence with belt programs
3. Greater use of statistical and analytic tools to measure and monitor results
4. Top line and bottom line accountability to justify improvements both in terms of customer satisfaction and cost
benefit analysis
Methodologies
Methodologies
Six Sigma projects follow two project methodologies :

DMAIC is used for projects aimed at

improving an existing business process.

1. DMAIC

2. DMADV
DMADV is used for projects aimed at
creating new product or process designs.

These methodologies, composed of five phases. 

Material Selection – Six Sigma Process

1. DMAIC
The DMAIC project methodology has Five phases:
Six Sigma Methodology for Process Improvement (DMAIC)

1. Define 

2. Measure

3. Analyze

4. Improve

5. Control

DMAIC is used, when the problem you want to solve is for a process that is already existing but not
meeting the expected levels of performance.
Material Selection – Six Sigma Process

DMAIC

1. Define the system, the voice of the customer and their requirements, and the project goals, specifically.

2. Measure key aspects of the current process and collect relevant data.

3. Analyze the data to investigate and verify cause-and effect relationships. Determine what the relationships are,
and attempt to ensure that all factors have been considered. Seek out root cause of the defect under
investigation.

4. Improve or optimize the current process based upon data analysis using techniques such as  design of
experiments, poka yoke or mistake proofing, and standard work to create a new, future state process. Set up
pilot runs to establish process capability.

5. Control the future state process to ensure that any deviations from target are corrected before they result in
defects. Implement control systems such as statistical process control, production boards, visual workplaces, and
continuously monitor the process.
Material Selection – Six Sigma Process

2. DMADV

DMADV project methodology has Five phase:

1. Define 

2. Measure

3. Analyze

4. Design

5. Verify DMADV is used when you want to set up/design a whole new process, that should be
meeting the desired level of performance from the beginning
Material Selection – Six Sigma Process
Material Selection – Six Sigma Process

DMADV
1. Define design goals that are consistent with customer demands and the enterprise strategy.

2. Measure and identify CTQs (characteristics that are Critical To Quality), product capabilities production process
capability, and risks.

3. Analyze to develop and design alternatives.

4. Design an improved alternative, best suited per analysis in the previous step

5. Verify the design, set up pilot runs, implement the production process and hand it over to the process owner(s).
Material Selection – Six Sigma Process
Material Selection – Six Sigma Process
SIX SIGMA PROCESS for MATERIALS SELECTION

A template for the materials selection process is created by condensing the overall process. The template
is a high-level flow chart designed to align with business goals and depict the involvement of different
areas of the organization.
 Material Selection – Six Sigma Process
Phase I: Product Planning
Phase II: Part Deployment
Customer driven product development
Design Phase III: Process Planning
Requirements Phase IV: Production planning
Voice of customer
Cu First step is to create customer selection matrix that
Sto represent all organizational functions related to
mer Parts product development.

Requirements
vo
ice
D Phase III: Process Phase IV:
e Planning Production
s planning
Phase I: Product
Planning i Process
g Requirements Production
n P Standards
Phase II: Part a P
Development r r
o
t c
s e
s
s
Material Selection – Six Sigma Process
Stake holder Interviews -
A questionnaire related to component details is developed for use in interviewing each stakeholder (VOC
interview). Interviews are conducted to obtain critical information and requirements from each organizational
function.
VOC addresses:
• Implications for customers
• Limitations associated with material search or change
• Customer needs and requirements
• Properties (e.g., mechanical) and service temperature capabilities
• Production limits such as design, assembly, and component manufacturing, Durability requirements such as
containment and component life
• Physical requirements such as weight, appearance, surface finish, and material consistency
• Current product strengths and weaknesses
• Product cost and performance tradeoffs

This information forms the technical requirements for the new material search initiative

• Input for a critical parameter tree (CPT).

• Measurable properties that are important to the material selection are obtained from CPT

The voice of business is understood at this stage.

Material Selection – Six Sigma Process
CPT – Critical Parameter Tree

The top parameters on the CPT

indicate key requirements
formulated from VOC interviews

Second-level parameters are

properties and aspects associated
with the material, process, cost, and
quality, which are key measures
defined for the future materials

Technical Specification freeze

These measures are narrowed

down based on application
requirements, which in turn are
submitted to suppliers as technical
specification requirements
Material Selection – Six Sigma Process
Voice of supplier

A potential supplier list is created from existing suppliers, purchasing department suggestions, and internet-
based research. After submitting a technical specification and request for quotation (RFQ) to suppliers, VOS is
conducted to understand supplier capabilities to deliver a strong candidate material(s) and correct manufacturing
process.

The VOS document completely outlines each supplier’s capability to provide the correct material, with specific
requirements including:

– Material options and availability

– Mechanical and physical properties and service temperature capability
– Material and manufacturing cost
– Manufacturing options (manufacturing steps)
– Production limits (e.g., design, assembly, and component manufacturing)
– Durability requirements (life of the material)
Material Selection – Six Sigma Process
QFD – Quality Function Deployment

The methodology of QFD[4] as a tool for new product development is useful in concept engineering
Material Selection – Six Sigma Process
Benchmark Selection from QFD
Material Selection – Six Sigma Process
Making Decisions

Materials concept selection. All materials information and relevant properties from suppliers and in-house testing
data are collected and loaded into the QFD benchmark section of the matrix to compare properties and rate key
properties to be input into both the PUGH matrix and cause and effects (C&E) matrix
Material Selection – Six Sigma Process
Cause & Effects (C&E) concept selection

The C&E matrix is also constructed using the data and information from the supplier and in-house testing. Key
process inputs are used to create an importance rating.
Concept selection can be narrowed down based on rankings and ratings from PUGH and C&E matrices.
Material Selection – Six Sigma Process
Pugh Method – (Similar to Digital method)