Redesign and manufacturing by using dmadv method

IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 04 Issue: 02 | Feb-2015, Available @ http://www.ijret.org 144
REDESIGN AND MANUFACTURING BY USING DMADV METHOD
Devendra G. Pendokhare1
, Taqui Quazi2
, Prasad S. Kulkarni3
1
PG Student, Mechanical Engineering Department, SCOE, Kharghar, Mumbai University, Maharashtra, India
2
HOD, Automobile Engineering Department, Saraswati college of engineering, kharghar, New Mumbai,
Maharashtra, India
3
Lecturer, Mechanical Engineering Department, Government Polytechnic, Vikramgad, MSBTE, Maharashtra, India
Abstract
The cost of poor Quality would help in analyzing the operating costs for effective and profitable business management. . In the era
of cut throat competition, especially in automobile sector, success of an organisation resides in its ability to respond quickly to the
needs of its customers. These customer needs must be attended with minimum manufacturing costs, minimum lead time to launch
the product in market and delivering better performance than the existing competitors in the market.success achieved by market
leaders is credited to their improvement initiatives. The customer needs must be attended with minimum manufacturing costs, and
delivering better performance than the existing competitors in the market. Therefore, Indian companies in order to compete with
global companies, it is very much essential to be at par, in all spheres of business aspects. Cost and Quality are two very
important aspects to be globally competitive, to capture market share, to retain customers to be in business and to achieve
business excellence. In the present times Six Sigma Methodology and QC Story are very famous and powerful tools and are widely
used in the global industries. The increase in demand of the growing customer looking for a better quality of product has
compelled corporations to adopt Six Sigma in order to improve the quality for enhanced competitive advantage. Therefore, it is
very much essential to understand relation between six sigma and cost of quality and its application in automobile industry.
Keywords: Six Sigma, DMADV, DMAIC, Quality improvement
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1. INTRODUCTION
Six sigma defines as a statistical concept that measures
process in terms of defects. He goes further to argue that
when used in business, it indicates defects in the outputs of a
process and helps one to understand how far the processes
deviate from perfection. it as a business strategy that seeks
to identify and eliminate causes of errors or defects or
failures in business processes by focusing on outputs that are
critical to customers. On the other hand defines it as a data
driven structured problem solving methodology for solving
chronic issues facing a business, and a breakthrough
business management process that is used to improve a
company’s performance by variation reduction.
Indian Automobile Industry has already started using Six
Sigma Methodology for vehicle design and process
improvement to survive in the global competition. It is very
important to study and investigate how Six Sigma
Methodology is employed in Indian Automobile Industry for
designing the product or for Process Improvement and
importance of Six Sigma Methodology to reduce Cost of
Quality. This motivates to take up research on this topic. In
the era of cut throat competition, success achieved by market
leaders is credited to their improvement initiatives. A
common element within many of these successful
companies is the use of powerful cost of poor quality
concepts in connecting improvement priorities to strategic
objectives, assessing the financial impact of poor quality,
understanding the root causes of poor quality, selecting high
payback improvement projects and managing the
Improvement initiative to simultaneously deliver improved
financial performance and greater customer satisfaction.
The customer needs must be attended with minimum
manufacturing costs, minimum lead time to launch the
product in market and delivering better performance than the
existing competitors in the market. Therefore Indian
companies in order to compete with global companies, it is
very much essential to be at par, in all spheres of business
aspects. Cost and Quality are two very important aspects to
be globally competitive, to capture market share, to retain
customers to be in business and to achieve business
excellence. Six Sigma is the powerful methodology to drive
improvement initiatives and reduce cost of quality.
Organizations choose to implement Six Sigma for numerous
reasons. Reasons for implementing Six Sigma can vary from
one organization to another, however, the list below present
the most common reasons for organizations to implement
Six Sigma to resolve issues facing the organization:
• Cost reduction
• Cycle time reduction
• Error and waste reduction
• Increase competitive advantage
• Improve customer satisfaction
• Increase shareholder value
• Change company culture
2. OBJECTIVES
 To study Six Sigma methodology extensively for both
improvement of existing process and design for Six
Sigma.
 To Study how Six Sigma methodology helps in
reduction of cost of poor quality.

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 To understand how Six Sigma methodology supports
Knowledge Management.
 To understand the synergic effect of the combination
of two powerful methods Lean and Six Sigma and its
positive impact in increasing speed and effectiveness
of any process within the organization.
 To study various applications and benefits of
implementing Six Sigma.
3. METHODOLOGY
Six Sigma is a management strategy that maximizes
customer satisfaction and minimizes the defects that create
customer dissatisfaction. Six sigma methodologies can be
used for improvement of process (called DMAIC) and also
is a powerful tool for new product design or improvement in
the existing product design (called DMADV). The five step
DMAIC approach of Six Sigma reduces the defects in
process, product or service. Flow charts, Pareto analysis,
Cause & Effect diagrams are the most frequently used basic
analysis and measurement tools by Six Sigma
implementation teams. Investigation as regards application
of Six Sigma methodology for process improvement in
Indian automobile industry is done and complete framework
is prepared and illustrated.
Fig-1: Six Sigma Methodology
 The Six Sigma DMAIC (Define, Measure, Analyze,
Improve, and Control) is an improvement system for
existing processes for incremental improvement.
 The Six Sigma DMADV (Define, Measure,
Analyze, Design, and Verify) is an improvement
system used to develop new processes or products.
4. DMADV
Fig-2: Road map for DMADV
 Define the project goals and customer (internal and
external) deliverables
 Measure and determine customer needs and
specifications
 Analyze the process options to meet the customer
needs
 Design (detailed) the process to meet the customer
needs
 Verify the design performance and ability to meet
customer needs
4.1 Define Problem or Opportunity
Problem is identified from voice of customer or from voice
of process. Voice of customer could be customer complaint
for performance / defect, field failure, critical customer
issues, etc. Voice of business could be internal defects, re-
work, internal rejections, internal quality issues, other
business issues etc. Define the goals of the new process.
Identify exactly what is being designed or changed. Why is
the change being made? Using the Quality Function
Deployment (QFD) or Analytic Hierarchical Process tools to
insure that the goals are compatible with consumer demand
and the company’s overall strategy.
Organizations may use right from 7 QC tools, Quality
Circles, Kizens, Small Group Activities to the modest tools
like Six Sigma Methodology or QC Story Approach for
problem solving depending upon the nature and complexity
of the problem. Where problem is chronic in nature and
problem is known, however, reasons are not known,
everything seems to be right, however, defects are getting
generated, and such complex problems are solved using Six
Sigma Methodology.

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Table-1: six sigma methodology for product design (DMADV)
Define Opportunity Measure
Performance
Analyze Opportunity Design New Product Verify Product Design
 Road map
define phase
 Sources of
capturing
voice of
customer
 Rules of
visiting
customers
 KJ / Affinity
diagram
 Road map
measure
phase
 Quality
function
deployment
(QFD)
 Advantages
of QFD
 Road map for
analyze phase
 Methods for critical
to Quality (CTQ)
 Methods for
concept selection
 TRIZ- theory of
inventive problem
solving
 Pugh matrix for
concept selection
 Road map for design
phase
 Failure mode and
effect analysis
 Robust design
 Taguchi quality loss
function
 Signal to noise
ration.
 Tolerance analysis
 Road map for verify
phase
 Reliability
 Design evaluation
 Design verification
tools
 Design review inputs
 Transfer to production
 Pilot production plan
 Design Validation
Summary of Define Phase is as follows
 Identify the projects which are linked to big Y.
 Select the team which is ready to contribute.
 Prepare team charter and get it approved.
 Train team members.
 Map the process
 Carry out value analysis.
 Walkthrough process.
 Analyze the past data from various view points.
 Identify quick wins and implement.
 Record results of quick wins.
4.2 Measurement Phase
In this phase data is gathered and analyzed that describes
with precision and accuracy. What is happening? What is
current or baseline, level of performance of the process that
creates the problem? It also produces some preliminary
ideas of possible causes for problem. Identify the
measurement standards that are important to stakeholders.
Convert customer needs into project objectives.
The goals of the measure phase are as follow
 Identify customers and their needs
 Derive specific requirements to the system
 Determine the corresponding output measures and
their target values and tolerances.
The significant improvement could be accomplished by:
 Reduction of cycle time,
 Reduction of control time,
 Reduction of tool costs, and
 Minimizing or eliminating scrap.
4.3 Analyze Phase
The analysis phase deals with identifying the critical factors
embedded in the current operation that could be improved to
minimize waste. Prior to starting this phase, the project
champion reviewed the collected data to filter out any type
of noise and disturbance. Data mining is then used to
identify main types of wastes for each machine to perform
the corrective actions. Develop design alternatives, identify
the best combination of requirements to provide value
within constraints, develop conceptual designs, evaluate,
select the best components and develop the best available
design. Analyse the alternatives available for meeting
project aims. Identify the behaviour of comparable best-in-
class designs.At this stage it is important not to miss out any
possible cause. If an important X is missed out, it will never
be analyzed for validation.
The tools used for listing Xs are:
 Brainstorming
 Process map
 Cause effect diagram
 Why-Why analysis
Prioritize Xs - After the Xs have been listed using process
map or cause effect diagram, these need to be prioritized.
The tools used to prioritize Xs are as follow
 Cause- Effect Matrix
 Pareto analysis
 Pugh Matrix
Validate Xs - There are three steps to validate Xs. They are
as follow.
 Scatter Plot
 Tolerance stack up analysis
 Design failure made & effects analysis
4.4 Design New Product
This stage of DMADV includes both a detailed and high
level design for the selected alternative. The elements of the
design are prioritized and from there a high level design is
developed. Once this step is complete, a more detailed
model will be prototyped in order to identify where errors
may occur and to make necessary modifications. Develop a
high level design, Develop exact specifications, Develop
detailed component designs, Develop related processes,
Optimize design. Design the new product, service, or
process. Utilize prognostic modelling, simulation,
prototypes, pilot trials, and other techniques in order to
confirm the design’s ability to meet the established aims of
the project.

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Fig-3: Key Steps Involved in Design Phase
4.4.1 Signal to Noise Ratio
The signals to noise ratio combines, in a single measure, information on both the average level and the spread of a variable. The
goal is to always maximize S/N ratio. The types of signal to noise ratios are
Lower is better ratio- applies to variables where lower value is preferable.
Higher is better ratio- applies to variables where a higher value is preferable.
Nominal is best ratio- applies to variables where deviations from a target value are undesirable
4.4.2 Tolerance Analysis
Tolerance analysis (TA) is the process of taking known tolerances and analyzing the combination of these tolerances at an
assembly level.
Fig-4: Tolerance Analysis
4.5 Verify Product Design
In the final phase, the team validates that the design is acceptable to all stakeholders. Will the design be effective in the real
world? Several pilot and production runs will be necessary to ensure that the quality is the highest possible. Here, expectations
will be confirmed, deployment will be expanded and all lessons learned will be documented. The Verify step also includes a plan
to transition the product or service to a routine operation and to ensure that this change is sustainable. Verify the efficiency of the
new product or process in a real world situation.
Fig-5: Steps involved in verify phase
4.5.1 Design Verification
It involves checking inputs/outputs at each stage as per
Design Verification Plan. It includes-
 Calculation Checks
 Peer review
 Proto test
 Lab trials
 Simulations
 Benchmarking with existing designs available in the
market
4.5.2 Design Reviews
Cross functional review to conform if design team has not
missed out on any key items such as
 Customer needs
 Manufacturability or assembly issues
 Serviceability issues
 Inspectability issues

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4.5.3 Transfer to Production
The implementation and the handover to the process owner
occur after the successful piloting.
4.5.4 Pilot Production Plan
Steps involved in pilot production are as follow
 Prepare pilot production plan
 Carry out the pilot production.
 Analyze the results
 Carry out optimization.
Most important tools used are as follow
 PDCA cycle
 Project Management tools (Gantt chart, Network
plan)
 Change management tools (Communication plan,
stake holder analysis)
 Documentation
 SOP s
 KPI systems
 Control Charts
 Process flow diagrams.
4.5.5 Design Validation
The objectives of design validation are
 To validate the design actually works in the real
operating environment
 May be part of initial design verification plan
document or may be developed separately
 If multiple applications are foreseen for new
product, plan to cover all possible
applications/environments in which the product is
likely to be used.
6. FUTURE SCOPE OF WORK
Investigation as regards application of six sigma
methodology to Indian automobile industry for reducing
cost of quality is done for manufacturing processes.
However as stated above, Six Sigma Methodology is
industry independent and it is applicable to all business
process. Viz. Purchasing, marketing, financial marketing,
finance etc. Future work may be taken up as follows.
 Application of six sigma for non manufacturing
processes in Indian automobile industry.
 Application of six sigma to Indian engineering
industry viz. non automobile companies.
 Application of six sigma in hospitality industry,
Application of six sigma in small scale industry.
7. CONCLUSION
In order for DMADV to be successful, the company will
need to understand the customer's needs and decide which
needs are being met and which needs should be improved
upon. Complete evaluations of the existing processes need
to be made in order to determine how you can satisfy your
customers while saving money.Six sigma is methodology
and a powerful quality improvement and design
improvement tool. Organizations that have adopted Six
Sigma indicate they have chosen it for several reasons.
Organizations indicated that they generally adopted the Six
Sigma technology in order to lower costs, increase time to
market, and improve both process and product and service
quality. In addition, they intended to institutionalize Six
Sigma as a company culture or state of mind. Organizations
implementing Six Sigma reveal product and service quality
improvement, cost reduction, and significant savings due to
Six Sigma projects focus on bottom line results. The success
of Six Sigma projects is also due to its results orientation,
data driven and ability to align the goals with objectives
across the organizations. It is used by Indian automobile
industry for supplier quality improvement. It helps in defect
reduction, process improvement, inventory reduction,
productivity improvement, reduction in customer
complaints, reduction in field returns, reduction in field
failures, reduction in warranty costs, and etc leading
reduction in Cost of Poor Quality. Lean is supportive to Six
sigma methodology & during the process walk through
value stream mapping is done to reduce waste (MUDA)
from the system.
ACKNOWLEDGMENTS
First of all, I would like to show my thanks and gratitude to
my project guide Prof. T. Z. Quazi for their time, effort and
guidance for the accomplishment of this project. To the
HOD, Prof. S. N. Teli, following my progress and correcting
my path the monitoring guidance and the advisor who was
always there. I also would like to express my thanks to the
Principal Dr. Manjush Deshmukh, for their contribution in
the paper work.
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BIOGRAPHIES
Devendra Gajanan Pendokhare
currently pursuing Masters Degree
Program in Manufacturing System
from Saraswati college of engineering,
Kharghar, New Mumbai, Maharashtra,
India, also working as Lecturer in
Government Polytechnic, Vikramgad in Mechanical
Engineering Department. BE in Mechanical Engineering
from Nagpur University.
T. Z. Quazi currently working as
Associate Professor and Head of
Department at Saraswati College of
Engineering, Kharghar, Navi Mumbai. He
has over 16 years of experience in
teaching field. He has published various
research papers in national and international journals
P. S. Kulkarni currently working as
Lecturer at Government Polytechnic,
Vikramgad. He has 20 years of
experience in teaching field. Completed
ME in Manufacturing Technology from
thapar university Patiyala.

Redesign and manufacturing by using dmadv method

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