Complexity reduction in product design and development using Design for Six Sigma

In this paper, we examine various aspects of complexity in product design and development, and propose a Total Cost of Complexity (TCC) equation to quantify the impact of non-value-added complexity. This paper attempts to conceptually link the complexity concepts to the Design for Six Sigma (DFSS) approach and looks at DFSS project types, project structure to match with complexity reduction efforts. We also discuss the DFSS project structure requirements for complexity reduction based on broad criteria and compare other kinds of structures against it. A model for DFSS evolution in an organisation is proposed covering various stages an organisation goes through during DFSS implementation. An automobile fluid connection case study clearly illustrates the DFSS approach to reduce component complexity and quantifies the benefits using the TCC equation.

[1]  Claude E. Shannon,et al.  A mathematical theory of communication , 1948, MOCO.

[2]  Clyde M. Creveling,et al.  Design for Six Sigma in Technology and Product Development , 2002 .

[3]  Nam P. Suh,et al.  Axiomatic Design Theory for Systems , 1998 .

[4]  Michael L. George,et al.  Lean Six Sigma : combining Six Sigma quality with lean speed , 2002 .

[5]  Nanua Singh.  Integrated product and process design: a multi-objective modeling framework , 2002 .

[6]  Abbie Griffin,et al.  The PDMA toolbook 2 for new product development , 2004 .

[7]  Nam P. Suh,et al.  principles in design , 1990 .

[8]  Kai Yang,et al.  The components of complexity in engineering design , 1999 .

[9]  N. Goodman,et al.  The Structure of Appearance. , 1953 .

[10]  Andrew Kusiak,et al.  Decomposition of the Design Process , 1993 .

[11]  Faysal Khalaf,et al.  Product Development Process: Views and Analysis , 2005 .

[12]  Mathew Thomas,et al.  Designing for Six Sigma Using Transfer Functions - An Automatic Transmission Transfer Gear Design Case Study , 2005 .

[13]  J. Kemeny.  Two Measures of Complexity , 1955 .

[14]  Durward K. Sobek,et al.  Involving suppliers in product development in the United States and Japan: evidence for set-based concurrent engineering , 1996 .

[15]  Qingyu Zhang,et al.  Learning and knowledge creation in product development: a LISREL analysis , 2004 .

[16]  Kai Yang,et al.  Design for Six Sigma , 2005 .

[17]  A. Kolmogorov.  Three approaches to the quantitative definition of information , 1968 .

[18]  C. E. SHANNON,et al.  A mathematical theory of communication , 1948, MOCO.

[19]  Kai Yang,et al.  Design for Six Sigma : A Roadmap for Product Development , 2003 .

[20]  I. Nonaka,et al.  The Knowledge Creating Company , 2008 .

[21]  R. J. Nelson,et al.  Structure of Complex Systems , 1976, PSA: Proceedings of the Biennial Meeting of the Philosophy of Science Association.

[22]  Charles F. Hockett,et al.  A mathematical theory of communication , 1948, MOCO.

[23]  Basem Said El-Haik,et al.  Axiomatic Quality: Integrating Axiomatic Design with Six-Sigma, Reliability, and Quality Engineering , 2005 .