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DesignforSixSigmaAdvancepraise‘Inhislatestbook,DesignforSixSigma,ChowdhuryeffectivelycommunicateshowtoturnSixSigmastrategyintoabreakthroughperformance.Chowdhury’sexcellentcontributionshowshowtomakeSixSigmapartofthewaywework–theunifyingframeworktoalignandenergizeanentirecompany.’DaveB.Burritt,SixSigmaDeploymentChampion,CaterpillarInc.‘SubirChowdhuryhaswrittenthequintessentialbookonDesignforSixSigmathatfillsacriticalneedforpublishedmaterialonthesubject.Thisinnovativebookprovidesaclearroadmapforallexecutives,businessmanagers,andSixSigmaleaderswhoareengagedinthecompetitiveracetobuildcost-effective,defect-freeprocessesandproductsthatwillwincustomersandguaranteetheirloyalty.’CynthiaCallas,VicePresidentofSixSigmaDeployment/BlackBelt,MerrillLynch‘Whydesignaprocessthatisn’toptimalandwillonlyneedSixSigmaimprovementslater?SubirChowdhury’smostimportantandtimelybooklaysthegroundworkusingDFSStoolstodesigntheprocesscorrectlythefirsttime,thussavingtime,effort,money,andmostofallcustomerfrustration.’Richard(Dick)Cunningham,ExecutiveSixSigmaChampionandDirectorofOperational&BusinessExcellence,JohnsManvilleCorporation–aBerkshireHathawayCompany‘Writteninaneasy-to-readstoryformat,Chowdhury’spreviousbook,ThePowerofSixSigma,providesaclearunderstandingofhowSixSigmacanbenefitanybusinessactivity.IawardallProjectChampionsacopyastheycompletetheirtrainingworkshopandrecommendallothersreaditaswell.Chowdhury’sDesignforSixSigmapromisestobejustaspowerfulandhelpful.’DouglasR.Pratt,P.E.,Director,SixSigmaProcessExcellence,DowCorningCorporation‘InordertotrulyattainSixSigmastatus,followingtheprocessoutlinedinChowdhury’sbook,DesignforSixSigma(DFSS),iscrucial.DFSSwillhelpyourcompanygreatlyincreaseitscompetitivestrength.’RobLindner,VicePresident,CorporateQuality,SunbeamCorporation‘Whetheryourproductistheresultofacomplextechnicalmanufacturingprocessorgroup-drivenideation,DesignforSixSigmaoffersaframeworktogetitrightthefirsttime.Withthisimportantandoutstandingnewbook,SubirChowdhurydriveshometheneedfortoday’sbusinessestounderstandtheircustomersbeforetryingtoservicethem.’RoxanneO’Brasky,President,InternationalSocietyofSixSigmaProfessionals(ISSSP)PEARSONEDUCATIONLIMITEDHeadOffice:EdinburghGateHarlowCM202JETel:+44(0)1279623623Fax:+44(0)1279431059LondonOffice:128LongAcreLondonWC2E9ANTel:+44(0)2074472000Fax:+44(0)2074472170Website:©SubirChowdhuryLimited2003TherightofSubirChowdhurytobeidentifiedasauthorofthisworkhasbeenassertedbyhiminaccordancewiththeCopyright,DesignsandPatentsAct1988ISBN0273662694BritishLibraryCataloguinginPublicationDataACIPcataloguerecordforthisbookcanbeobtainedfromtheBritishLibraryAllrightsreserved;nopartofthispublicationmaybereproduced,storedinaretrievalsystem,ortransmittedinanyformorbyanymeans,electronic,mechanical,photocopying,recording,orotherwisewithouteitherthepriorwrittenpermissionofthepublishersoralicencepermittingrestrictedcopyingintheUnitedKingdomissuedbytheCopyrightLicensingAgencyLtd,90TottenhamCourtRoad,LondonW1P0LP.Thisbookmaynotbelent,resold,hiredoutorotherwisedisposedofbywayoftradeinanyformofbindingorcoverotherthanthatinwhichitispublished,withoutthepriorconsentofthepublishers.Thispublicationisdesignedtoprovideaccurateandauthoritativeinformationinregardtothesubjectmattercovered.Itissoldwiththeunderstandingthatneithertheauthorsnorthepublisherisengagedinrenderinglegal,investing,oranyotherprofessionalservice.Iflegaladviceorotherexpertassistanceisrequired,theserviceofacompetentprofessionalpersonshouldbesought.Thepublisherandcontributorsmakenorepresentation,expressorimplied,withregardtotheaccuracyoftheinformationcontainedinthisbookandcannotacceptanyresponsibilityorliabilityforanyerrorsoromissionsthatitmaycontain.10987654321TypesetbyNorthernPhototypesettingCo.Ltd,BoltonPrintedandboundinGreatBritainbyBiddlesLtd,Guildford&King’sLynnThepublishers’policyistousepapermanufacturedfromsustainableforests.DesignforSixSigmaSubirChowdhuryAnimprintofPearsonEducationLondonNewYorkTorontoSydneyTokyoSingaporeHongKongCapeTownNewDelhiMadridParisAmsterdamMunichMilanStockholmDedicationTomyfriend,co-authorandmentorDrGenichiTaguchi.Thisbookwouldneverhavematerializedwithoutthecontinuoushelpofthefollowingcolleaguesandfriends:AlanWuBarryBebbShinTaguchiBradWalkerASI–AmericanSuppliersInstituteAcknowledgmentsxiAbouttheauthorxiiiPrefacexv1DFSS:theonlywaytoachieveSixSigma1PartIPeoplePowerofDFSS2DFSSimplementationstrategy293PeoplerolesinDFSS54PartIIProcessPowerofDFSS:IDDOV4Identifyanddefineopportunity755Developconcepts1056Optimizethedesign1317Verifythedesign153Glossary172Bibliography176Index179ContentsIwouldliketoextendenormousgratitudetothemanwhotaughtallofusthepowerofRobustEngineering–DrGenichiTaguchi.Iamveryfortunatetoworkcloselywiththisgenius.Histeachinginspiresmeeveryday.DrArmandV.Feigenbaum,PhilipB.CrosbyandJ.D.PowerIIIhavealsobeenagreatinspiration
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