Design for Six Sigma in product and service development : applications and case studies

439 Pages·2012·7.996 MB·English

by  Elizabeth A Cudney, Sandra L Furterer

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Applications and Case Studies provides step-by-step analysis and practical
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Black Belts act as mentors and prepare you to touch actual data and make l
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decisions when embarking on real-world projects. Even after you’ve mastered i
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the techniques, the breadth and depth of coverage contained in this book will

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ISBN: 978-1-4398-6060-1
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Edited by
www.crcpress.com
9 781439 860601
Elizabeth A. Cudney and Sandra L. Furterer
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K12783 cvr mech.indd 1 4/25/12 9:00 AM

Design for Six Sigma
in Product and
Service Development
Applications and Case Studies

Design for Six Sigma
in Product and
Service Development
Applications and Case Studies
Edited by
Elizabeth A. Cudney and Sandra L. Furterer
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2012 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Version Date: 20120420
International Standard Book Number-13: 978-1-4398-6640-5 (eBook - PDF)
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I would like to dedicate this book to my mother, who has always
given to me. Whether it was support, time, or of herself, she has been
a constant role model in living a gratifying life for others. I would
also like to dedicate this book to my late father, who set an example
for me on how to find balance personally and professionally.
Finally, I would like to dedicate this book to my children, Caroline
and Joshua, and my husband Brian. My children never cease to
amaze me and give me joy, support, and inspiration. I am truly lucky
to have such a supportive and loving husband and family.
Beth Cudney
I dedicate this book to my loving family, my husband Dan, and my children
Kelly, Erik, and Zachary, who provide constant support and the true
purpose in my life. My children provide the incentive for me to strive for
excellence to be a guiding example for their lives. A special thanks to my
son Zachary for staying up late with me as I wrote and edited the book.
I also dedicate this book to my parents, Joan and the late Mel Brumback,
who instilled in me the value of education and a lifelong love of books
and learning, and also to my siblings, Dan, Neil, Tim, and Kathy, who
encouraged the competitive spirit and being our best in all we do.
Sandy Furterer

Contents
Preface.......................................................................................................................ix
Acknowledgments..................................................................................................xi
About.the.Editors.................................................................................................xiii
List.of.Design.for.Six.Sigma.Project.Team.Members.and.
Contributing Authors............................................................................................xv
1 Instructional Strategies for Using This Book............................................1
Elizabeth Cudney and Sandra Furterer
2 Design for Six Sigma Identify-Define-Design-Optimize-
Validate (IDDOV) Roadmap Overview......................................................5
Sandra Furterer and Elizabeth Cudney
Section I Product Design for Six Sigma Projects
3 Design of a Walker—A Design for Six Sigma Case Study...................51
Anas AlGhamri, Çiğdem Sheffield, Lisette Sandoval, Elizabeth Cudney,
and Sandra Furterer
4 Design of a Military Tool Holder—A Design for Six Sigma Case
Study................................................................................................................81
David Moore, Antonio Ward, Bruce Lane, Thomas Fitzpatrick, Elizabeth
Cudney, and Sandra Furterer
5 Design of a Can Crusher—A Design for Six Sigma Case Study.......103
Amogh Shenoy, Austin Das, Sagnik Saha, Sumant Joshi, Elizabeth
Cudney, and Sandra Furterer
6 Design of a Hazardous Chemical Cleanup System—A Design
for Six Sigma Case Study...........................................................................133
Benjamin Dowell, James Baker, Prajakta Bhagwat, Neil Kester, Elizabeth
Cudney, and Sandra Furterer
7 Design of Radio-Frequency Coverage for Wireless
Communications—A Design for Six Sigma Case Study.....................159
Roger Ates, Elizabeth Cudney, and Sandra Furterer
8 Solar-Heated Jacket—A Design for Six Sigma Case Study................185
Nick Paul, Josef Garcia, Adam Samiof, Elizabeth Cudney, and Sandra Furterer
vii
viii Contents
9 Traveling Jewelry Box—A Design for Six Sigma Case Study............209
Robert Jackson, Kayla Najjar, Elizabeth Cudney, and Sandra Furterer
10 Design of an Optical Mouse—A Design for Six Sigma
Case Study...............................................................................................239
Priya Dhuwalia, Soundararajan Chandra Moleeswaran, Swathi Priya
Pedavalli, Vishwanath Narayanan, Elizabeth Cudney, and Sandra Furterer
11 Design of a Duffel Bag—A Design for Six Sigma Case Study..........265
Jason Castro, Colby Krug, Patrick McCarthy, Elizabeth Cudney,
and Sandra Furterer
Section II Service Process Design for Six Sigma Projects
12 Design of Women’s Center Service Processes—A Design for
Six Sigma Case Study.................................................................................291
Sandra Furterer
13 Project Charter Review Process Design— A Design for
Six Sigma Case Study.................................................................................339
Sandra Furterer
14 Information Technology (IT) System Changes—A Design for
Six Sigma Case Study.................................................................................391
Patricia Long, Jamison Kovach, David Ding, Elizabeth Cudney, and
Sandra Furterer
15 The Future and Challenges of Design for Six Sigma..........................415
Elizabeth Cudney and Sandra Furterer