IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308

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 The customer needs must be attended with minimum
manufacturing costs, minimum lead time to launch the
Six sigma defines as a statistical concept that measures product in market and delivering better performance than the
process in terms of defects. He goes further to argue that existing competitors in the market. Therefore Indian
when used in business, it indicates defects in the outputs of a companies in order to compete with global companies, it is
process and helps one to understand how far the processes very much essential to be at par, in all spheres of business
deviate from perfection. it as a business strategy that seeks aspects. Cost and Quality are two very important aspects to
to identify and eliminate causes of errors or defects or be globally competitive, to capture market share, to retain
failures in business processes by focusing on outputs that are customers to be in business and to achieve business
critical to customers. On the other hand defines it as a data excellence. Six Sigma is the powerful methodology to drive
driven structured problem solving methodology for solving improvement initiatives and reduce cost of quality.
chronic issues facing a business, and a breakthrough
business management process that is used to improve a Organizations choose to implement Six Sigma for numerous
company’s performance by variation reduction. reasons. Reasons for implementing Six Sigma can vary from
one organization to another, however, the list below present
Indian Automobile Industry has already started using Six the most common reasons for organizations to implement
Sigma Methodology for vehicle design and process Six Sigma to resolve issues facing the organization:
improvement to survive in the global competition. It is very • Cost reduction
important to study and investigate how Six Sigma • Cycle time reduction
Methodology is employed in Indian Automobile Industry for • Error and waste reduction
designing the product or for Process Improvement and • Increase competitive advantage
importance of Six Sigma Methodology to reduce Cost of • Improve customer satisfaction
Quality. This motivates to take up research on this topic. In • Increase shareholder value
the era of cut throat competition, success achieved by market • Change company culture
leaders is credited to their improvement initiatives. A
common element within many of these successful
2. OBJECTIVES
companies is the use of powerful cost of poor quality
concepts in connecting improvement priorities to strategic  To study Six Sigma methodology extensively for both
objectives, assessing the financial impact of poor quality, improvement of existing process and design for Six
understanding the root causes of poor quality, selecting high Sigma.
payback improvement projects and managing the  To Study how Six Sigma methodology helps in
Improvement initiative to simultaneously deliver improved reduction of cost of poor quality.
financial performance and greater customer satisfaction.
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IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308

 To understand how Six Sigma methodology supports  Define the project goals and customer (internal and
Knowledge Management. external) deliverables
 To understand the synergic effect of the combination  Measure and determine customer needs and
of two powerful methods Lean and Six Sigma and its specifications
positive impact in increasing speed and effectiveness  Analyze the process options to meet the customer
of any process within the organization. needs
 To study various applications and benefits of  Design (detailed) the process to meet the customer
implementing Six Sigma. needs
 Verify the design performance and ability to meet
3. METHODOLOGY customer needs
Six Sigma is a management strategy that maximizes
4.1 Define Problem or Opportunity
customer satisfaction and minimizes the defects that create
customer dissatisfaction. Six sigma methodologies can be Problem is identified from voice of customer or from voice
used for improvement of process (called DMAIC) and also of process. Voice of customer could be customer complaint
is a powerful tool for new product design or improvement in for performance / defect, field failure, critical customer
the existing product design (called DMADV). The five step issues, etc. Voice of business could be internal defects, re-
DMAIC approach of Six Sigma reduces the defects in work, internal rejections, internal quality issues, other
process, product or service. Flow charts, Pareto analysis, business issues etc. Define the goals of the new process.
Cause & Effect diagrams are the most frequently used basic Identify exactly what is being designed or changed. Why is
analysis and measurement tools by Six Sigma the change being made? Using the Quality Function
implementation teams. Investigation as regards application Deployment (QFD) or Analytic Hierarchical Process tools to
of Six Sigma methodology for process improvement in insure that the goals are compatible with consumer demand
Indian automobile industry is done and complete framework and the company’s overall strategy.
is prepared and illustrated.
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.
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

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Volume: 04 Issue: 02 | Feb-2015, Available @ http://www.ijret.org 145
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308

Table-1: six sigma methodology for product design (DMADV)

Define Opportunity Measure Analyze Opportunity Design New Product Verify Product Design
Performance
 Road map  Road map  Road map for  Road map for design  Road map for verify
define phase measure analyze phase phase phase
 Sources of phase  Methods for critical  Failure mode and  Reliability
capturing  Quality to Quality (CTQ) effect analysis  Design evaluation
voice of function  Methods for  Robust design  Design verification
customer deployment concept selection  Taguchi quality loss tools
 Rules of (QFD)  TRIZ- theory of function  Design review inputs
visiting  Advantages inventive problem  Signal to noise  Transfer to production
customers of QFD solving ration.  Pilot production plan
 KJ / Affinity  Pugh matrix for  Tolerance analysis  Design Validation
diagram concept selection

Summary of Define Phase is as follows select the best components and develop the best available
 Identify the projects which are linked to big Y. design. Analyse the alternatives available for meeting
 Select the team which is ready to contribute. project aims. Identify the behaviour of comparable best-in-
 Prepare team charter and get it approved. class designs.At this stage it is important not to miss out any
 Train team members. possible cause. If an important X is missed out, it will never
 Map the process be analyzed for validation.
 Carry out value analysis.
 Walkthrough process. The tools used for listing Xs are:
 Analyze the past data from various view points.  Brainstorming
 Identify quick wins and implement.  Process map
 Record results of quick wins.  Cause effect diagram
 Why-Why analysis
4.2 Measurement Phase
Prioritize Xs - After the Xs have been listed using process
In this phase data is gathered and analyzed that describes map or cause effect diagram, these need to be prioritized.
with precision and accuracy. What is happening? What is The tools used to prioritize Xs are as follow
current or baseline, level of performance of the process that  Cause- Effect Matrix
creates the problem? It also produces some preliminary  Pareto analysis
ideas of possible causes for problem. Identify the  Pugh Matrix
measurement standards that are important to stakeholders.
Convert customer needs into project objectives. Validate Xs - There are three steps to validate Xs. They are
as follow.
The goals of the measure phase are as follow  Scatter Plot
 Identify customers and their needs  Tolerance stack up analysis
 Derive specific requirements to the system  Design failure made & effects analysis
 Determine the corresponding output measures and
their target values and tolerances.
4.4 Design New Product
The significant improvement could be accomplished by: This stage of DMADV includes both a detailed and high
 Reduction of cycle time, level design for the selected alternative. The elements of the
 Reduction of control time, design are prioritized and from there a high level design is
 Reduction of tool costs, and developed. Once this step is complete, a more detailed
 Minimizing or eliminating scrap. model will be prototyped in order to identify where errors
may occur and to make necessary modifications. Develop a
4.3 Analyze Phase high level design, Develop exact specifications, Develop
detailed component designs, Develop related processes,
The analysis phase deals with identifying the critical factors Optimize design. Design the new product, service, or
embedded in the current operation that could be improved to process. Utilize prognostic modelling, simulation,
minimize waste. Prior to starting this phase, the project prototypes, pilot trials, and other techniques in order to
champion reviewed the collected data to filter out any type confirm the design’s ability to meet the established aims of
of noise and disturbance. Data mining is then used to the project.
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,
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Volume: 04 Issue: 02 | Feb-2015, Available @ http://www.ijret.org 146
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308

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 4.5.2 Design Reviews

It involves checking inputs/outputs at each stage as per Cross functional review to conform if design team has not
Design Verification Plan. It includes- missed out on any key items such as
 Calculation Checks  Customer needs
 Peer review  Manufacturability or assembly issues
 Proto test  Serviceability issues
 Lab trials  Inspectability issues
 Simulations
 Benchmarking with existing designs available in the
market
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IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308

4.5.3 Transfer to Production and a powerful quality improvement and design

improvement tool. Organizations that have adopted Six
The implementation and the handover to the process owner Sigma indicate they have chosen it for several reasons.
occur after the successful piloting. Organizations indicated that they generally adopted the Six
Sigma technology in order to lower costs, increase time to
4.5.4 Pilot Production Plan market, and improve both process and product and service
Steps involved in pilot production are as follow quality. In addition, they intended to institutionalize Six
 Prepare pilot production plan Sigma as a company culture or state of mind. Organizations
 Carry out the pilot production. implementing Six Sigma reveal product and service quality
improvement, cost reduction, and significant savings due to
 Analyze the results
Six Sigma projects focus on bottom line results. The success
 Carry out optimization.
of Six Sigma projects is also due to its results orientation,
data driven and ability to align the goals with objectives
Most important tools used are as follow
across the organizations. It is used by Indian automobile
 PDCA cycle industry for supplier quality improvement. It helps in defect
 Project Management tools (Gantt chart, Network reduction, process improvement, inventory reduction,
plan) productivity improvement, reduction in customer
 Change management tools (Communication plan, complaints, reduction in field returns, reduction in field
stake holder analysis) failures, reduction in warranty costs, and etc leading
 Documentation reduction in Cost of Poor Quality. Lean is supportive to Six
 SOP s sigma methodology & during the process walk through
 KPI systems value stream mapping is done to reduce waste (MUDA)
 Control Charts from the system.
 Process flow diagrams.
ACKNOWLEDGMENTS
4.5.5 Design Validation
First of all, I would like to show my thanks and gratitude to
The objectives of design validation are my project guide Prof. T. Z. Quazi for their time, effort and
 To validate the design actually works in the real guidance for the accomplishment of this project. To the
operating environment HOD, Prof. S. N. Teli, following my progress and correcting
 May be part of initial design verification plan my path the monitoring guidance and the advisor who was
document or may be developed separately always there. I also would like to express my thanks to the
 If multiple applications are foreseen for new Principal Dr. Manjush Deshmukh, for their contribution in
product, plan to cover all possible 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.
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Volume: 04 Issue: 02 | Feb-2015, Available @ http://www.ijret.org 149