Problem Solving Methods - DFSS, DMADV & IDOV

Question 1

What is DMADV?

Answer 1

define, measure, analyze, design, verify

Question 2

What is the purpose of the define phase of DMADV?

Answer 2

define the process or product-design goals

Question 3

What is the purpose of the measure phase of DMADV?

Answer 3

to measure (and identify) critical-to-quality aspects of your process/product

Question 4

What is the purpose of the analyze phase of DMADV?

Answer 4

to develop a process or product design and evaluate to select the best design

Question 5

What is the purpose of the design phase of DMADV?

Answer 5

design the new process or product, and to optimize and test your design

Question 6

What is the purpose of the verify phase?

Answer 6

to verify performance and the ability to meet design goals and customer needs

Question 7

What is the difference between DMAIC and DMADV?

Answer 7

DMAIC - improve existing processes
DMADV - establish a new process

Question 8

High level differences between DMAIC & DMADV

Answer 8

DMAIC DMADV
find and fix existing defects design new products and services
eliminate waste discover and prevent defects
logic and creativity logic, creativity, and emotion
make things right compete in emerging/unknown

Question 9

Working level differences between DMAIC & DMADV

Answer 9

DMAIC DMADV
plants, manufacturing marketing, R&D, design,
reactive, detecting, reducing proactive, preventing, generating
local solution cross-functional/culture change
population to study no population to study
uncertainty from variation uncertainty from unknowns
empirical empirical and theoretical
absolute metrics relative metrics
financial benefits quantifiable challenging to quantify financial

Question 10

What is IDOV?

Answer 10

identify, design, optimize, validate

a methodology used for designing products and services by focusing on:
1) identifying the customers needs
2) designing a product or service to meet those needs
3) optimizing the product or the service
4) then validating that the solution does meet the needs

Question 11

What design forms does DMADV or IDOV take?(4)

Answer 11

1) cost
2) manufacturing
3) efficiency
4) maintainability

Question 12

What are the activities of the identify phase of IDOV? (4)

Answer 12

1) identify customer and product requirements
2) establish business case
3) identify tech requirements, critical to quality variables, and specification limits
4) establish roles, responsibilities, and milestones

Question 13

What are the tools of the identify phase of IDOV? (6)

Answer 13

1) project charter
2) project plans
3) value stream map
4) customer needs map
5) quality function deployment
6) SIPOC

Question 14

What are the activities of the design phase of IDOV? (4)

Answer 14

1) developing concept design
2) identifying potential risks
3) identifying design boundaries for each technical requirement
4) plan procurement

Question 15

What are the tools of the design phase of IDOV? (4)

Answer 15

1) hypothesis tests
2) analysis tools
3) design of experiments
4) FMEA

Question 16

What are the activities of the optimize phase of IDOV? (4)

Answer 16

1) evaluating process capability to meet critical to quality limits
2) optimizing design
3) optimizing sigma and cost
4) enhancing design for robust and reliable performance

Question 17

What are the tools of the optimize phase of IDOV? (3)

Answer 17

1) future state map
2) statistical process control
3) control plan

Question 18

What are the activities of the verify phase of IDOV? (4)

Answer 18

1) prototype testing and validation
2) assessing performance, failure modes, risks and reliability
3) design iterations
4) final phase review

Question 19

What are the tools of the verify phase of IDOV? (2)

Answer 19

1) FMEA
2) product testing/tools software

Question 20

What are the differences between IDOV and DMAIC?

Answer 20

IDOV DMAIC
new processes existing processes
evaluates customer needs first compares process perf.
target condition process capability
qual/soft data hard/quant data

Question 21

What is the product life cycle?

Answer 21

all the stages of development of a product from development to decline and removal from the market

Question 22

What are the product or service lifecycle phases? (5)

Answer 22

1) Ideation (conceive, specify, assess, plan)
2) Design (define, design, systematic analysis, prototype, test, analyze, verify)
3) Production (finance, launch, manufacture, produce, build, procure, market, sell, relaunch, deliver)
4) Service (use, work, operate, service, maintain, improve, support, upgrade, retire, reclaim, recycle, end of life, disposal)
5) Administration

Question 23

How is the product life cycle managed?

Answer 23

by portfolio management, product lifecycle management, or product/process lifecycle management functions

Question 24

What is Design for Six Sigma (DFSS)?

Answer 24

a methodology that focuses on integrating customer requirements into the product design to prevent defects

Question 25

When is DMADV used in DFSS?

Answer 25

when a process does not exist at our company and needs to be developed

OR

when a process or product does exist and has been optimized, but it still does not meet the level of expectations that the customers have or stays lower than six sigma level

Question 26

How is IDOV used in DFSS?

Answer 26

used primarily in the manufacturing and product development world to design a new product or service

Question 27

When is DMAIC used instead of DFSS?

Answer 27

when a product or a process exists at your company, but is not able to meet the specified customer expectations, specifications, or is not able to perform adequately and has not been optimized yet