Application Of Six Sigma Methodology In IR Coated Halogen Lamp Development Projects

Design for six sigma (DFSS) is the one of the core methodologies in six sigmamanagement system; it is developed from the traditional six sigma improvementmethodology (DMAIC), and it is also different with DMAIC. By the establishment ofa integration new product development process, design for six sigma methodologyunderstands and collect the customer needs accurately, and come out the new productwith robust design. Finally, achieve the six sigma quality target with low developmentcost.As DMAIC, DFSS has its own particular process. However, still no commonprocess for DFSS up to now. This article picks the process which was developed bySubir Chowdhur; the process is defined as IDDOV. For detail, the process is foridentify, define, design, optimize and verify.Base on the research for six sigma methodology in the IR coated halogen lampdevelopment projects, we analysis and collect the customer needs by the method ofKANO model and quality function deployment. We utilize the methodology of Trizand DFMEA for product concept design. At product design phase, we establish theproduct's transfer function by DOE and ANOVA; optimize the product parameter toachieve robust design. We also predict product quality by Monte Carlo simulation;increase the efficiency of product development process and reduce the developmentcost in the same time. To guide following new product introduction work, we processthe hypothesis test to ensure the design quality.