2. Generate ideas for saving – each person 30 ideas.

Boot Camp 为节约出主意 ---- 每个人 30 个

• Alternate materials - plastic vs. metal / 材料更换 --- 塑料 vs 金属

• Alternate manufacturing process for components - stamped vs. machined/ 加工工艺更换 --- 冲压 vs 机加工
• Identify parts with high weight – can the weight be reduced by alternate materials? By design analysis? 零件重量能否减轻？
可更换材料？由设计部门进行分析？
• Can multiple parts be combined into one part? 多个零件是否可以集合成一个？
• Standard parts - is there a standard part that can be used vs. a custom? 是否有标准件可用而不是特别设计的？
• Reduce / commonize / eliminate fasteners 减少 / 共用 / 消除紧固件
• Challenge custom build versus standard 挑战客户定制 vs 标准
• Combine multiple components into single component 集合多个零件为一个零件
• Packaging – can it be reduced / eliminated? Can it do more than just store the box during shipment? Is it as cost effective
as possible? Does it need to be a specific color or is natural corrugated OK?
包装—是否可以减少或消除？ 盒子除了运输以外可否有其他功能利用 ? 是需要特别的颜色还是可以自然色也可以 ?
• Color - does a component need to be a specific color? Is a standard color OK vs. custom? Is black and white acceptable? 颜
色—零件是否是特别指定的颜色？标准色是否可以 vs 客户指定？黑色或者白色可以接受？
• Secondary process elimination – Can a plated part be replaced with a material that does not require plating? Can a
secondary operation be replaced by near net shape process? 子流程的消除 --- 电镀的零件是否更换成不需电镀材料？
• Other - if it ships to the customer, it‘s part of the product cost! 其他 --- 交给客户的东西就是产品成本的一部分
• Labels, instruction sheets, printed material – necessary? Can these be part of the product or packaging vs. a stand alone
component? 标签， 说明书，打印材料 --- 必要的？ 这些是产品上就带有的还是独立的零部件？
• Can a technical manual be replaced by a CD or website? 技术手册可以用 CD 或网络下载来替代？
• Surface finish – will a highly processes surface be visible in the end product? Is a surface preparation required for
form/fit/function? 表面处理 --- 精密处理过的表面在终端产品中是可见的面？一个工作面只是为了成形 / 配合 / 功能？
• Challenge tolerances 挑战公差

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 2. Generate ideas for saving.
Boot Camp 为节约出主意
- Look for MUDA 寻找浪费
- High scrap (this is a good place almost everyone can look), low FPY processes, over-designed (reduce material), high returns,
tight tolerances ask why? 对高报废率（这是每个人都能看到的），低一次通过率， 过度设计（减少材料），高退货
率，太小的公差问为什么
- Areas that have not had multiple good Standard work Kaizens or are new to DHR/ 没有进行多轮标准工作改善或者是
DHR 的新成员？
- Areas that have not had aggressive PPV attention like LCR sourcing activities/ 没有积极进取 PPV 目标的区域比如没有 LCR
采购活动
- New products that did not follow the 3P process or did not engage cross-functional teams and suppliers during
development, and were released not meeting TG3 cost goals/ 没有遵循 3P 流程设计出来的新产品 , 或者是在开发阶段没
有进行交叉训练的团队和供应商 , 没有达到 TG3 成本目标的产品 .
- Newer products that are not selling or not competitive/ 行情不好或者竞争力不强的产品
- Older products that still produce good margins and still have life in them, but haven’t been touched in a long time/ 仍有好
的利润的在生产的但是很长时间没动过的老产品
- Areas that have not had a strong VAVE culture/ 还没有建立 VAVE 文化的区域
- Areas that are focused on new product development with little Sustaining Engr resource and Mfg Engr resource/ 缺乏支持
和制造工程资源但又集力于的新产品开发区域
- Areas that are more General Sales/platform/higher volume oriented instead of OEM/design to spec, or lower volume
sales / 以常规销售 / 平台 / 高销量为导向而不是 OEM 或特别设计 , 低销售量

2
Overview
VAVE Process Flow Chart
VAVE Boot Camp
VAVE 流程图
VAVA 训练营

5 Days VAVE Kaizen

五天改善
Identified opportunities
确定机会

Does Boot Camp

Pre-work can cover the needs to do VAVE
Funnel for some feasible items No/ 否 Final report of VAVE kaizen
训练营前期工作已提供了进行漏斗改善 VAVE 最终报告
的准备资料 .

Yes/ 是
Choose those items Which can be done in

1.
2 days VAVE Funnel.
Do Funnel just after Boot Camp.
Can complete items with No/ 否
Funnel kaizen
2. Schedule for other Funnel if 可以在漏斗阶段做完
necessary.
选择可以在两天漏斗改善内完成的项目 .

3.
4.
在训练营结束后立即进行漏斗改善
必要时 , 排出其他漏斗改善计划
Yes/ 是
Final report of Funnel
漏斗改善的最终报告 3
 VAVE Focus Areas
VAVE 关注领域
High
Don’t Secondary
高 Touch 不用 Focus 次关注
碰 点
Customer value
客户关注度

Don’t Primary
Touch 不用 Focus 主要关注
碰 点

Low
低
Low 低 Product Cost 产品成本 High 高
4
 2. Review VOC and prepare QFD chart.
审核 VOC 并制定QFD图表
--3.Rank Customer Needs and Wants Using Bubble Sort

VAVE Funnel --3 使用冒泡 " 分类法将客户的需求排列等级

Rank Customer Needs and Wants Using Bubble Sort 使用泡泡图将客户的需求进行排

列

(Row+Column)

Reliability

Column Sum
Light Way
Function
Accuracy

Durable

Row Sum
Safety

Multi-
Feature

Sum
Feature
Number

1 Safety 5 - 1 1 1 1
1 5 0
2 Reliability 3 - - 1 1
1 3 0
3 Accuracy 4 - - - 1 1
1 3 1
4 Multi-Function 1 - - - - 1 1 0
5 Durable 2 - - - - - 1 1 1
6 Light Way 0 - - - - - - 0 0
0 0 1 0 1 0
For each item in the form, ask “which is more important, row or column?”
If row is more important, place 1 in the box, if column is more important, leave empty. Work all
the way down column A with the team. 对表格中的每一分析对象 , 问”列重要还是行重要” ,
如果是行重要在对应的方格内写” 1”, 如果列重要就让方格为空 , 最后计算出各行” 1” 的
总数放于各行后面 , 各列空格总数放于各列下方 , 对应的” 1” 和”空格”之和置于各行的
5
前面
 2. Review VOC and prepare QFD chart.
审核 VOC 并制定 QFD 图表
VAVE Funnel --4. Summarize Rank of Customer Needs and Wants
--4 对客户的需求进行打分汇总

Feature QFD
Feature Sort QFD list and rank Team Rank
Number Rank
1 Safety 5 Safety 5 5
2 Reliability 3 Accuracy 4 4
3 Accuracy 4 Reliability 3 3
4 Multi-Function 1 Durable 2 2
5 Durable 2 Multi-Function 1 1
6 Light Way 0 Light Way 0 1
Copy “special-values’ the first two columns to the 3-4 columns. Then sort on
‘recopied rank’ in descending order for a forced rank. The team makes the final
ranking (1-5) by consensus. 将”特别数值”中前两列复制到 3-4 列 , 再复制一
份清单放于表格右侧并按降序强制排列 , 小组成本讨论决定最后的排列分值 .

6
 2. Review VOC and prepare QFD chart.
审核 VOC 并制定 QFD 图表
VAVE Funnel --5. Develop Competitive Assessment from Customer View
从客户的角度制定竞争对手评估表

Existing POLO 17B

competitive 1
(MMastech SS8217)
Features competitive 2
(UUni-T TT60C)
Customer competitive 3
Requirements (VVictor CC890C+)

Worse

Best
Relative Importance(1 Low, 5 High)
1 2 3 4 5
Safety 5
Accuracy 4
Reliability 3
Durable 2
Multi-Function 1
Light Way 1

7
 2. Review VOC and prepare QFD chart.
审核 VOC 并制定 QFD 图表
VAVE Funnel --6. Product features/functions 产品特性 / 功能

Test Leads
Housing

Fuse
competitive 2

PCA

LCD
(UUni-T TT60C)
Customer competitive 3
Requirements (VVictor CC890C+)

Worse

Best
Relative Importance(1 Low,
5 High)
1 2 3 4 5
Safety 5
Accuracy 4
Reliability 3
Durable 2
Multi-Function 1
Light Way 1

Notes or Values for

Metrics(optional)

Score for cumulative Customers

needs

8
 2. Review VOC and prepare QFD chart. 审核 VOC 并制定 QFD 图表
--6. Product features/functions 产品特性 / 功能
-----Product Customer correlation 产品客户相关性
VAVE Funnel

• We now rate how these product features/functions meet customer

requirements using low, medium and high scale (l, m, h). It is OK to use
negative values (nl, nm, nh), if product function/feature adversely affects
customer requirement 用低，中，高（ l,m,h ）评估这些产品的特性／
功能满足客户要求的程度如何，如果产品特性／功能向反方向影响了
客户的需求，用负值也是允许的（ nl,nm,nh)
• Calculate impact of product feature/function on customer value by
multiplying it with relative customer importance. For calculations use h=9,
m=3, l=1 通过将产品特性乘以相关客户重要性来计算产品特性／功能
对客户关注点的影响程度 , 用 h=9,m=3,l=1 进行计算 .
• As an example, head support has high impact on accessibility for the
doctor. It is rated as h since relative importance of accessibility to the
doctor is 5, its contribution to score is 9*5 = 45, 例如 , 头部支架对医生来
说有很高的影响系数 , 它的分值打为” h” 因为它的相关重要性对医生
来说是 5, 最后分值计算的结果就是 9*5=45

9
 2. Review VOC and prepare QFD chart. 审核 VOC 并制定 QFD 图表
VAVE Funnel --7. Weigh Product Functions/features 产品功能 / 特性权重

Features

competitive 1

Test Leads
(MMastech SS8217)

Housing

Fuse
competitive 2

PCA

LCD
(UUni-T TT60C)
Customer competitive 3
Requirements (VVictor CC890C+)

Worse

Best
Relative Importance(1 Low,
5 High)
1 2 3 4 5
Safety 5 h m h h
Accuracy 4 h m
Reliability 3 h m h
Durable 2 h h h
Multi-Function 1 h
Light Way 1 l m

Notes or Values for

Metrics(optional)

Score for cumulative Customers

136 9 36 45 102
needs

10
 2. Review VOC and prepare QFD chart. 审核 VOC 并制定 QFD 图表
--8. Improvement area of Product Functions/features
VAVE Funnel 产品功能 / 特性提升领域

Competitive Assessment
Features
Existing POLO 17B
competitive 1

Test Leads
(MMastech SS8217)

Housing
competitive 2

Fuse
PCA

LCD
(UUni-T TT60C)
Customer competitive 3
Requirements (VVictor CC890C+)

Worse

Best
Relative Importance(1 Low,
5 High)
1 2 3 4 5
Safety 5 h m h h
Accuracy 4 h m
Reliability 3 h m h
Durable 2 h h h
Multi-Function 1 h
Light Way 1 l m

Notes or Values for

Metrics(optional)
Score for cumulative Customers
136 9 36 45 102
needs
Cost of feature/funtion ($) ￥97.61 ￥7.72 ￥24.20 ￥14.84 ￥6.00
Redesign Feasibility(y/n) Y Y Y N Y

11
 2. Review VOC and prepare QFD chart.
审核 VOC 并制定 QFD 图表
VAVE Funnel --9. QFD Process /QFD 流程

Competitive Assessment
Features
Existing POLO 17B
competitive 1

Test Leads
(MMastech SS8217)

Housing

Fuse
competitive 2
PCA

LCD
(UUni-T TT60C)
Customer competitive 3
Requirements (VVictor CC890C+)

Worse
Relative Importance(1 Low,
5 High)
1 2 3 4
Safety 5 h m h h
Accuracy 4 h m
Reliability 3 h m h
Durable 2 h h h
Multi-Function 1 h
Light Way 1 l m

Notes or Values for

VAVE LCR VAVE LCR
Metrics(optional)

Score for cumulative Customers

136 9 36 45 102
needs
Cost of feature/funtion ($) ￥97.61 ￥7.72 ￥24.20 ￥14.84 ￥6.00
Redesign Feasibility(y/n) Y Y Y N Y

12
 7. Review ideas with QFD and identify opportunity items
用 QFD 进行改善意见分析并确定改善机会
VAVE Funnel

Evaluation of Designs 评估设计

13