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8 Solar-Heated Jacket—A Design for Six Sigma Case Study

Nick Paul, Josef Garcia, Adam Samiof, Elizabeth Cudney, and Sandra Furterer

CONTENTS

8.1. Project.Overview........................................................................................ 186 8.1.1. Project.Description......................................................................... 186 8.1.2. Project.Description......................................................................... 186 8.1.3. Project.Goal...................................................................................... 187 8.1.4. Requirements.and.Expectations................................................... 187 8.1.5. Project.Boundaries.......................................................................... 187

8.2. Identify.Phase.Activities............................................................................ 187 8.2.1. Identify.Phase.................................................................................. 188

8.2.1.1. Project.Charter.................................................................. 188 8.2.1.2. Perform.Stakeholder.Analysis........................................ 188 8.2.1.3. Develop.Project.Plan........................................................ 188 8.2.1.4. Gantt.Chart....................................................................... 189

8.2.2. Identify.Phase.Case.Discussion.................................................... 191 8.3. Define.Phase.Activities.............................................................................. 191

8.3.1. Define.Phase.................................................................................... 191 8.3.1.1. Collect.Voice.of.the.Customer.

(VOC) Information.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 8.3.1.2. Ranking.Customer.Requirements................................. 193 8.3.1.3. Identify.Critical.to.Satisfaction.(CTS).

Measures and.Targets...................................................... 193 8.3.1.4. Translate.Voice.of.the.Customer.(VOC).into.

Technical.Requirements.............................................. 193 8.3.2. Define.Phase.Case.Discussion...................................................... 197

8.4. Design.Phase.Activities............................................................................. 199 8.4.1. Design.Phase................................................................................... 199

8.4.1.1. Identify.Design.Concepts............................................... 199

186 Design for Six Sigma in Product and Service Development

8.1 Project Overview

8.1.1 Project Description

To. develop. the. solar-heated. jacket,. given. the. product. name. “IJacket,”. a. specific. methodology,. Design. for. Six. Sigma. (DFSS),. was. used. to. optimize. results..DFSS.is.a.business.and.engineering.analysis.methodology.that.uses. tools. to. introduce. new. technology,. products,. processes,. and. services. to. market.. It. places. the. focus. up-front. in. the. design. or. engineering. process.. The.goal.is.to.avoid.manufacturing.or.service.process.problems.using.sys- tems. engineering. techniques. from. the. start.. DFSS. enables. this. by. focus- ing. the. team. on. understanding. the. voice. of. the. customer. (VOC). and. the. customer’s. specific. requirements. that. create. detailed. engineering. speci- fications.. The. end. result. is. a. robust. solution. that. is. optimized. to. reduce. the.impact.of.variation..The.product.or.service,.as.a.result,.requires.fewer. adjustments. and. thus. less. money. is. spent. correcting. problems.. The. basic. idea. is. to. understand. customer. requirements. before. production. to. reduce. costly.corrective.measures.

8.1.2 Project Description

Currently,. there. are. several. jackets. that. are. heated. using. battery. power. providing. extra. warmth. as. well. as. a. few. that. can. charge. portable. elec- tronic.devices.using.solar.power..The.team’s.idea.was.to.create.a.jacket.that. incorporates.both.of.these.technologies.while.still.satisfying.the.expected. quality.that.a.winter.jacket.should.fulfill..To.ensure.the.jacket.would.meet. our.target.market’s.demand,.the.team.sought.customer.feedback.to.guide. the.process.

8.4.1.2. Design.the.Product:.Select.the.Concept........................ 200 8.4.1.3. Design.for.X.(DFX).Methods.......................................... 201

8.4.2. Design.Phase.Case.Discussion..................................................... 203 8.5. Optimize.Phase.Exercises......................................................................... 204

8.5.1. Optimize.Phase............................................................................... 204 8.5.2. Optimize.Phase.Case.Discussion................................................. 205

8.6. Validate.Phase.Activities........................................................................... 205 8.6.1. Validate.Phase................................................................................. 205 8.6.2. Validate.Phase.Case.Discussion................................................... 206

8.7. Conclusions.................................................................................................. 207

187Solar-Heated Jacket—A Design for Six Sigma Case Study

8.1.3 Project Goal

The.goal.of.the.project.is.to.create.a.jacket.that.is.capable.of.providing.extra. warmth. through. an. interior. heating. system.. It. will. also. be. able. to. provide. power. to. various. electronics. such. as. cell. phones,. iPods,. MP3. players,. and. possibly. even. larger. devices,. depending. on. the. VOC.. Our. aim. is. to. sell. at. a. competitive. price. point. comparable. to. other. winter. jackets.. Ideally,. the. IJacket. would. sell. for.not.much.more. than.a.normal.winter. jacket,.making. the.additional.features.much.more.attractive.to.customers.

8.1.4 Requirements and Expectations

The.IJacket.will.require.flexible.and.durable.solar.panels.that.can.be.attached. to.the.jacket..The.solar.panels.will.need.to.be.weather.resistant.and.capable. of.working.in.cold.temperatures..We.expect.our.customers.to.find.the.added. technology.of.the.jacket.a.major.delight.and.key.factor.in.differentiating.our. product.in.the.market..The.jacket.should.be.able.to.provide.constant.heating. and.charging.capabilities.when.in.direct.sunlight.and.store.up.to.3.hours.of. power.when.indoors.

8.1.5 Project Boundaries

•. The.IJacket.will.use.existing.technology. •. It.will.only.be.able.to.sustain.heating.and.charging.one.device.at.the.

same.time. •. The. IJacket. will. primarily. be. geared. toward. outdoor. enthusiasts.

ages.18.to.39.

8.2 Identify Phase Activities

It.is.recommended.that.students.work.in.project.teams.of.three.to.four.stu- dents.throughout.the.DFSS.case.study.

. 1.. Develop Project Charter:.Use.the.information.provided.in.the.Project. Overview.section.to.develop.a.project.charter.for.the.DFSS.project.

. 2.. Perform Stakeholder Analysis:.Perform.a.stakeholder.analysis,.iden- tifying.project.stakeholders.

. 3.. Develop Project Plan:. Develop. your. team’s. project. plan. for. the. DFSS. project.

188 Design for Six Sigma in Product and Service Development

8.2.1 Identify Phase

8.2.1.1 Project Charter

The.first.step.was.to.develop.a.project.charter.

Project Name:.IJacket Project Overview:.To.design.a.solar-powered.jacket.with.heated.interior.

and.a.mobile.power.source. Problem Statement:.There.is.a.recent.influx.of.small.electronics.carried.

constantly.by.individuals.in.need.of.a.power.source..Included.in.this. problem.is.the.fact.that.many.customers.use.small.electronics.in.the. outdoors.and.likely.in.cold.environments..Heated.jackets.exist.on.a. 12.V.system..However,.a.greener.design.using.solar.energy.would.be. better.for.the.customer..A.different.jacket.exists.with.a.small.power. source,. but. its. fashion. does. not. appeal. to. all. possible. customers.. Our.expectation.is.to.make.the.jackets.fashionable.by.incorporating. colors. and. logos. of. sports. teams.. We. will. also. include. a. means. of. charging.small.electronics.and.integrating.a.sound.system.for.musi- cal.enjoyment.

Customer/Stakeholders:. We. expect. the. largest. group. of. customers. to. be.outdoor.lovers.and.sports.enthusiasts,.or.possibly.even.sports. teams.. The. customers. would. also. include. those. who. are. con- stantly.traveling.

Goal of the Project:. Create. a. fashionable,. green,. and. affordable. solar- powered.jacket.with.all.the.bells.and.whistles.

Scope Statement:.We.will.focus.on.reducing.costs.to.make.it.more.afford- able.while.maintaining.the.green.and.fashionable.concept.

Projected Financial Benefit(s):. Gain. the. majority. of. the. market. share. by. selling.the.jackets.in.the.$200.price.range.

8.2.1.2 Perform Stakeholder Analysis

The.stakeholder.analysis.was.performed.to.identify.the.project.stakeholders.. The.stakeholder.analysis.definition.is.shown.in.Figure 8.1.

8.2.1.3 Develop Project Plan

The.IJacket.project.was.managed.by.using.a.Gantt.chart..The.Gantt.chart. is.a.way.to.place.an.expected.timeline.on.the.team.in.order.to.ensure.the. project.is.finished.on.time..This.ensures.the.product.is.out.to.market.before. the. competition. in. order. to. gain. market. share.. Although. speed. is. impor- tant,. speed. needs. to. be. balanced. with. quality. assurance. measures.. To.

189Solar-Heated Jacket—A Design for Six Sigma Case Study

accomplish. this,. we. constructed. gates. at. each. phase. that. included. using. templates. and. checklists. from. the. DFSS. methodology.. We. also. required. the.approval.or.counsel.of.a.DFSS.expert.on.each.task.before.moving.to.the. next.task.or.phase..The.general.phases.of.the.project.followed.the.process. of.IDDOV.(Identify-Define-Design-Optimize-Validate).

8.2.1.4 Gantt Chart

The. Gantt. chart. (shown. in. Figure 8.2). was. simplified. for. ease. of. reading. and.brevity.

All. the. tasks. listed. in. the. Gantt. chart. were. completed. in. series. because. of. the. gate. requirements.. However,. many. of. the. subtasks. were. completed. in.parallel.by.different.individuals.from.the.working.team..Each.individual. then. brought. the. completed. subtask. to. a. group. meeting. where. the. group. reviewed.and.approved.the.work..Rapid.and.effective.communication.is.par- amount.to.successful.project.management..Each.member.of.the.team.must. understand. his. or. her. role. on. the. team. and. the. expected. inputs. that. he. or. she.must.provide..The.environment.of.our.working.group.allowed.for.face- to-face.communication.three.to.four.times.a.week..The.group.also.had.other. projects. together,. which. enabled. cross. talk. and. periodic. progress. reports. throughout.the.week..Our.group.has.worked.and.socialized.together.before. the. IJacket. project. and. continued. the. same. group. dynamic. that. produced. previous.success..Good.communication.enabled.each.member.of.the.team.to. participate.in.any.discussion.and.provide.input.on.the.project..Our.methods. of. communication. included. face-to-face. conversation,. written. correspon- dence,.and.telephone.conferences.

Stakeholder Name Stakeholder Role on Project Impact/Concerns

•.Customer •.Key.outdoor.enthusiasts. who.would.purchase.and. wear.the.solar-heated. jacket

•.Durable.jacket •.Functional •.Relatively.low.cost •.Self-contained.heat.source

•.Project.team •.Project.team.members. who.will.design.the.jacket

•.Apply.DFSS.tools.and. methodology

•.Meet.customer.requirements

•.Project. champion.

•.Project.champion,.also. course.instructor.who. teaches.the.Design.for.Six. Sigma.(DFSS).tools.and. methodology

•.Ensure.the.teams.learn.and.apply. the.DFSS.tools.and.methodology

•.Ensure.the.customer.requirements. are.met.through.the.product. design

FIGURE 8.1 Stakeholder.analysis.definition.

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Date in Day/Month 2-Jan 26-Jan 9-Feb 23-Feb 9-Mar 23-Mar 6-Apr 20-Apr 4-May

Task

Receive.the.assignment

Develop.project.charter

Perform.Voice.of.the.Customer

Perform.market.analysis

Create.quality.function.deployment.(QFD)

Complete.House.of.Quality.(HOQ)

Perform.concept.development

Develop.concept.selection/optimization

Validate.final.report

Develop.final.report

Present.results/final.report

FIGURE 8.2 Project.plan.

191Solar-Heated Jacket—A Design for Six Sigma Case Study

8.2.2 Identify Phase Case Discussion

. 1.. DFSS.Project.Charter:.Review.the.project.charter.presented.

. a.. A.problem.statement.should.include.a.view.of.what.is.going.on. in.the.business.and.when.it.is.occurring..The.project.statement. should. provide. data. to. quantify. the. problem.. Does. the. prob- lem. statement. provide. a. clear. picture. of. the. business. problem?. Rewrite.the.problem.statement.to.improve.it.

. b.. The. goal. statement. should. describe. the. project. team’s. objective. and. be. quantifiable,. if. possible.. Rewrite. the. goal. statement. to. improve.it.

. c.. Did. your. project. charter’s. scope. differ. from. the. example. pro- vided?.How.did.you.assess.what.was.a.reasonable.scope.for.your. project?

. 2.. Project.Plan

. a.. Discuss. how. your. team. would. develop. their. project. plan. and. how.they.assigned.resources.to.the.tasks..How.would.the.team. determine.estimated.durations.for.the.work.activities?

8.3 Define Phase Activities

. 1.. Collect VOC:. Create. a. VOC. survey. to. understand. the. current. and. potential.customers’.requirements.

. 2.. Identify critical to satisfaction (CTS) measures and targets:.Based.on.the. VOC,.determine.the.CTS.measures.and.then.develop.targets.using. benchmarking.data.

. 3.. Translate VOC into technical requirements:. Using. the. CTS. measures. and.targets,.identify.the.technical.requirements.for.the.product.

8.3.1 Define Phase

8.3.1.1 Collect Voice of the Customer (VOC) Information

To. implement. the. voice. of. the. customer. into. the. design. process,. we. con- ducted.a.survey.that.was.mainly.targeted.at.our.key.demographic.of.18-.to. 39-year-old. outdoor. enthusiasts.. Essentially,. we. wanted. feedback. from. the. population.that.would.most.likely.have.a.need.or.desire.for.the.IJacket..Some. of. the. activities. we. saw. our. target. market. participating. in. were. attending. football.games,.hiking,.skiing/snowboarding,.and.hunting.

Our. survey. was. conducted. online,. consisted. of. nine. questions,. and. was. taken. by. 49. individuals.. The. respondents. were. given. choices. for. most.

192 Design for Six Sigma in Product and Service Development

questions.to.help.narrow.the.survey.but.were.given.an.opportunity.toward. the.end.of.the.survey.to.identify.any.features.they.would.desire.on.a.jacket. that.were.not.included.in.the.survey.

The.key.information.derived.from.the.survey.is.as.follows:

•. 92%.of.our.target.audience.was.represented.(i.e.,.outdoor.enthusiasts). •. 47%. football. spectators,. 53%. hunting,. and. 56%. skiing/snowboard-

ing.were.the.largest.populations. •. 67%.wait.3.years.or.longer.to.buy.a.new.jacket. •. The. average. temperature. for. household. thermostats. was. centered.

between.68.and.70°F. •. 35%.showed.a.strong.interest.in.the.general.concept.for.the.IJacket.

with.73%.neutral.or.better. •. Fit,.comfort,.and.warmth.were.the.most.important.features.of.the.jacket. •. Team.logos.were.undesirable.to.customers. •. 67%.want.to.pay.less.than.$250.with.the.additional.features. •. The.respondents.were.willing.to.pay.more.for.additional.features. •. 35%. of. those. who. responded. to. our. write-in. question. stated. that.

numerous/well-positioned. pockets. were. a. key. feature. of. a. jacket. they.would.own.

After. analyzing. the. raw. customer. data. we. developed. some. essential. cus- tomer.requirements:

•. Warm,.comfortable,.and.fit.well •. Lots.of.storage •. Integrate.with.iPods/MP3.players •. Cost.less.than.$250 •. Convertible.(adapt.to.changes.in.temperatures) •. Durable •. Adjustable

Finally,.we.translated.these.requirements.into.functional.requirements.(FRs). that.could.satisfy.customer.requirements..Some.of.the.important.functional. requirements.were

•. Solar-powered.heating •. Numerous.and.secure.pockets •. Earbud.routing.and.iPod/MP3.storage.compartments •. Removable.layers

193Solar-Heated Jacket—A Design for Six Sigma Case Study

•. Breathable.fabric •. Moisture-controlling.fabric •. Glove.integration

8.3.1.2 Ranking Customer Requirements

After. identifying. the. needs,. we. needed. to. next. rank. the. customer. require- ments.and.identify.their.importance..Again,.we.took.the.VOC.from.our.sur- vey.to.understand.the.importance.of.each.requirement,.shown.in.Figure 8.3.

8.3.1.3 Identify Critical to Satisfaction (CTS) Measures and Targets

8.3.1.3.1 Market Analysis

Our.next.step.was.to.analyze.the.competitors.in.our.market.against.our.cus- tomer.requirements.as.shown.in.Figure.8.4..We.decided.to.benchmark.our. product. against. an. existing. battery-powered,. solar-powered,. and. regular. winter.jacket..Thorough.research.was.conducted.to.find.jackets.that.were.tar- geting.our.current.market.and.that.were.sold.near.our.price.point..The.solar. jacket.was.the.only.jacket.that.was.slightly.above.our.target.price.range,.but. currently.it.is.the.only.solar-powered.jacket.on.the.market.that.we.could.find.

8.3.1.4 Translate Voice of the Customer (VOC) into Technical Requirements

8.3.1.4.1 Quality Function Deployment

Our.next.step.was.to.use.quality.function.deployment.(QFD).to.further.refine. the.grouped.VOC.data..QFD.uses.the.data.to.develop.a.clear,.ranked.set.of. product.development.requirements..The.House.of.Quality.(HOQ).tool.was. used.as.our.primary.tool.for.QFD..The.HOQ.transforms.the.VOC.into.tech- nical. and. business. performance. requirements.. It. allows. us. to. understand. the. correlations. between. our. customer. requirements. and. the. functional. requirements. we. developed.. The. HOQ. will. show. us. which. requirements. have. strong. relationships. with. each. other. and. if. we. have. missed. fulfilling. any. customer. requirements.. It. will. also. show. us. if. we. have. incorporated. a. functional. requirement. that. the. customer. does. not. desire.. The. House. of. Quality.is.shown.in.Figures.8.5,.8.6,.and.8.7.

8.3.1.4.2 Functional Requirements Relationship (Top of House of Quality)

We. next. needed. to. understand. the. relationships. between. the. functional. requirements.. Sometimes. two. functional. requirements. individually. will. make.your.product.more.robust,.but.the.combination.of.the.two.can.have.a. negative.impact..For.example.in.our.HOQ,.we.found.that.increasing.solar- powered. heating. and. the. number. of. layers. would. both. add. to. the. comfort. of. the. jacket.. However,. if. both. were. increased,. at. a. certain. point. it. would.

194 Design for Six Sigma in Product and Service Development

make.the.jacket.too.hot.and.uncomfortable..Improving.both.at.the.same.time. can. possibly. reduce. the. comfort. and. thus. reduce. the. customer. satisfaction. with.the.jacket..Through.the.HOQ.we.identified.a.number.of.relationships. between.the.functional.requirements.that.will.be.considered.when.develop- ing.concepts.

8.3.1.4.3 Functional Requirement Targets

Based.on.the.VOC.and.the.existing.products.in.the.market,.we.established. target. limits. for. each. of. the. functional. requirements.. To. facilitate. design- ing.concepts.we.included.the.difficulty.of.each.target,.which.was.primarily. based.on.the.added.cost.that.each.requirement.would.add.to.the.jacket.

8.3.1.4.4 Kano Analysis

To. further. understand. the. VOC,. we. next. conducted. a. Kano. analysis. as. shown. in. Figure. 8.8.. The. Kano. analysis. breaks. customer. satisfaction. into. three. categories:. basic. needs. that. must. be. in. the. future. product,. linear.

Rank Customer Requirement Importance

1 Fit/comfort 5

2 Warmth 5

3 Body.surface.coverage.(keeping.forearms,.face,.and.neck.covered. from.cold)

4 Storage 5

5 iPod/MP3.integration 4

6 Price.(positive.indicates.an.increase.in.price) 4

7 Temperature.regulation.versus.climate.(as.temperatures.change,. jacket.is.still.comfortable)

8 Temperature.regulation.versus.individual.(different.people.desire. different.warmth)

9 Convertible.(changing.jacket.by.removing.features) 4

10 Durability 3

11 Adjustability.(adjusting.jacket.to.body) 3

12 Compatibility 3

13 Charging.capability 2

14 Style/design 1

15 Climate.responsiveness 1

FIGURE 8.3 Customer.requirement.ranking.

195Solar-Heated Jacket—A Design for Six Sigma Case Study

satisfiers. that. produce. proportional. satisfaction. with. their. increased. pres- ence.in.the.future.product,.and.delighters.that.the.customer.is.satisfied.with- out.but.make.the.product.exponentially.more.appealing..Understanding.the. customer.requirements.for.the.first.two.categories.is.extremely.important.in. producing. a. product. that. customers. would. consider. purchasing.. The. final. category.helps.us.understand.the.features.that.will.distinguish.our.product. and. promote. sales.. We. established. these. different. categories. based. on. the. feedback. from. our. survey. and. from. customer. needs. defined. by. what. they. do;.essentially.analyzing.the.popular.jackets.people.are.currently.buying.

•. Expected.quality.(not.requested,.but.assumed.present) •. Water.resistant •. Strong.fabric

Customer Requirement Importance Competitor A

Battery Powered Heated Jacket

Solar Powered Heated Jacket 1 2 3 4 5

Fit/comfort 5 4 4 4

Warmth 5 4 3 3

Body surface coverage (Keeping forearms, face, and neck covered from cold)

5 4 3 4

Storage 5 3 3 2

iPod/MP3 integration 4 3 1 5

Price (Positive indicates an increase in price) 4 3 4 2

Temperature regulation vs. climate (As temps change jacket is still comfortable)

4 3 4 3

Temperature regulation vs. individual (Different people desire different warmth)

4 1 4 1

Convertible (Changing jacket by removing features) 4 5 1 4

Durability 3 4 3 4

Adjustability (Adjusting jacket to body) 3 4 2 2

Compatibility 3 5 3 4

Charging capability 2 1 2 5

Style/design 1 4 4 4

Climate responsiveness 1 4 2 2

Competitor A Competitor B Competitor C

FIGURE 8.4 Market.analysis.

196 Design for Six Sigma in Product and Service Development

•. Hood •. Retractable.hood •. Secure.pockets

•. One-dimensional.quality.(specifically.requested) •. Underarm.vents •. Comfortable.fabric •. Moisture.control •. Thickness

Customer Requirements and Functions Requirements Relationship Matrix

Quality Characteristics (Functional requirements

or hows)

Demanded Quality (Customer requirement or whats)

Fit/comfort

Warmth

Body surface coverage (Keeping forearms, face, and neck covered from cold) Storage

iPod/MP3 integration

Price (Positive indicates an increase in price) Temperature regulation vs. climate (As temps change jacket is still comfortable) Temperature regulation vs. individual (Different people desire different warmth) Convertible (Changing jacket by removing features) Durability

Adjustability (Adjusting jacket to body) Compatibility

Charging Capability

Style/design

Climate responsiveness

= Strong relationship

= Moderate relationship

= Weak relationship

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FIGURE 8.5 Quality.function.deployment.House.of.Quality.

197Solar-Heated Jacket—A Design for Six Sigma Case Study

•. Removable.layers •. Numerous.pockets

•. Exciting.quality.(unknown.to.the.customer,.delighters,.wow.factor) •. Heated.hood •. Breathable.fabric.(for.a.winter.coat) •. Glove.integration •. Earbud.routing •. Solar-powered.heating •. Solar-powered.charging

8.3.2 Define Phase Case Discussion

. 1.. How. did. your. team. perform. the. VOC. collection?. How. could. VOC. collection.be.improved?

. 2.. Did. your. team. create. and. distribute. a. customer. survey,. and. if. so,. what.is.the.appropriate.statistical.analysis.to.perform.to.identify.the. importance.of.the.customers’.requirements?

. 3.. Did. you. perform. a. quality. function. deployment?. How. did. you. identify. the. technical. requirements. and. the. correlations. between. customer.and.technical.requirements?

. 4.. What.is.the.value.of.using.the.Kano.model.in.your.VOC.analysis?

= Strong positive correlation

= Positive correlation

= Negative correlation

= Objective is to minimize

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FIGURE 8.6 Top.of.House.of.Quality.

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FIGURE 8.7 Functional.requirements.targets.

199Solar-Heated Jacket—A Design for Six Sigma Case Study

8.4 Design Phase Activities

. 1.. Identify.design.concepts..Develop.the.design.concepts.

. 2.. Design.the.product.and.select.the.concepts.

8.4.1 Design Phase

8.4.1.1 Identify Design Concepts

8.4.1.1.1 Concept Generation

Concept 1:.Our.first.concept.was.termed.the.“Cadillac”.option.because. it. would. go. above. and. beyond. in. all. facets. of. quality. and. capabil- ity.. The. concept. is. defined. by. having. a. strong. heating. and. charg- ing. capability.. Another. distinctive. feature. is. the. ability. to. detach. the.solar.cells.from.the.jacket..In.addition,.the.jacket.would.have.a. heated.hood,.thermostat.heating.control,.iPod/MP3.integration.with. earbud.routing.up.through.the.collar,.thin.and.breathable.material,. lots.of.pockets,.and.be.composed.of.multiple.layers.

Concept 2:.Our. second. concept. was. termed. the.“Extreme.Conditions”. option,. because. it. would. be. appropriate. for. someone. who. enjoys. activities. such. as. mountain. climbing. where. weather. extremes. are. experienced.. This. concept. is. defined. by. having. the. most. powerful.

Exciters (Delighters): • Underarm vents • Comfortable fabric • Moisture control • �ickness • Removable layers • Numerous pockets

Expected (Basic needs): • Water resistant • Strong fabric • Hood • Retractable hood • Secure pocketsVery Unsatisfied

Very Satisfied

Basic Needs

Linear Satisfier

Fully Achieved

Did not Achieved

Delighter

• Heated hood • Breathable fabric (for a winter coat) • Glove integration • Ear bud routing • Solar powered heating • Solar powered charging

One-dimensional (Linear):

FIGURE 8.8 Kano.model.for.product.

200 Design for Six Sigma in Product and Service Development

solar.cells.in.order.to.provide.large.amounts.of.heat..In.addition,.the. jacket.would.incorporate.glove.integration,.jacket–pants.integration,. thick.and.durable.material,.rotary.heating.control,.an.integrated.face. shield,.and.no.iPod/MP3.integration.

Concept 3:. Our. third. concept. was. termed. the. “Temperate/Moderate. Conditions”.option..It.was.intended.to.be.made.for.climates.where. there. is. not. a. large. swing. in. the. weather. conditions.. This. concept. would.have.smaller.solar.cells,.an.on/off.switch.for.heating,.a.non- heating.hood,.limited.pockets,.and.no.electronic.charging.capability.

Concept 4:. Our. fourth. concept. was. termed. the. “Athletic”. option.. This. concept.was.designed.for.people.who.actively.participate.in.sports.. Some.of.the.key.features.that.define.this.concept.are.thin,.breathable. material,.comfortable.fabric,.underarm.vents,.iPod/MP3.integration. with. earbud. routing,. smaller. solar. cells. for. less. heating. capability,. rotary.heating.control,.glove.integration,.and.multiple.layers.

Concept 5:. Our. fifth. concept. was. termed. the. “Styled”. option. because. it. was. meant. for. a. consumer. interested. in. appearing. fashionable. and. trendy.. Some. of. the. key. features. that. define. this. concept. are. a.retractable.hood,.charging.capability,.iPod/MP3.integration.with. earbud.routing,.no.heating.capability,.and.multiple.layers.

Concept 6:.Our.sixth.concept.was.termed.the.“Convertible”.option..This. option. was. meant. to. exhibit. versatility. in. its. use. and. capabilities.. Some. features. of. this. option. include. a. retractable. hood,. underarm. vents,.multiple.layers,.numerous.pockets,.glove.integration,.moder- ate.solar.heating,.and.limited.charging.capability.

Concept 7:. Our. seventh. concept. was. termed. the. “Storage”. option. because. it. was. intended. to. accommodate. a. customer. who. likes. to. carry.lots.of.electronics..This.option.contains.features.such.as.strong. charging. capability,. glove. integration,. limited. heating. capability,. iPod/MP3.integration.with.earbud.routing,.and.numerous.pockets.

8.4.1.2 Design the Product: Select the Concept

8.4.1.2.1 Pugh’s Concept Selection

In. order. to. begin. this. process,. we. started. by. defining. the. concept. selection. criteria. to. conduct. our. analysis.. Due. to. the. manageable. amount. of. VOC. requirements,.we.decided.to.use.all.of.them.when.comparing.our.seven.con- cepts..The.VOC.requirements.are.listed.in.priority,.as.indicated.by.the.results. of.our.survey..Next,.we.chose.a.best-in-class.datum.to.compare.our.concepts.. We.chose.to.use.Competitor.1.from.our.competitive.analysis.in.our.House.of. Quality.as.the.datum.because.it.was.the.highest.rated.compared.to.our.VOC.. We. then. conducted. our. analysis. of. the. seven. concepts. using. the. standard. +. (better),. S. (same),. –. (worse). symbols. to. denote. its. comparison. with. the.

201Solar-Heated Jacket—A Design for Six Sigma Case Study

datum..We.then.compiled.the.results.from.the.seven.concepts,.and.the.results. are.shown.in.Figure 8.9.

Our.initial.analysis.of.the.results.indicated.the.Cadillac.option,.Convertible. option,. and. Storage. option. were. the. strongest. options. compared. to. the. datum..We.then.compared.the.three.options.to.see.differences.in.the.ratings.. Many. of. the. higher-ranked. requirements. shared. the. same. rating. among. all. three. with. the. lower-ranked. requirements. showing. the. differences.. We. were.able.to.further.our.concept.using.the.price.criterion..Our.projections.of. price.for.these.three.concepts.indicated.we.could.meet.the.customer.require- ment.for.less.than.$250.with.the.Convertible.option.and.the.Storage.option,. but.not.the.Cadillac.option..We.decided.to.form.a.hybrid.option.by.making. trade-offs.using.the.voice.of.the.customer.and.the.price.point.we.intended.to. meet..Our.superior.concept.contains.the.following.features.and.is.pictured. in.Figure 8.10:

•. Moderate-to-strong.heating.capability •. Moderate.charging.capability •. Multiple.layers •. Glove.integration •. iPod/MP3.integration.with.earbud.routing •. Underarm.vents •. Retractable,.heated.hood •. Numerous.pockets.(internal.and.external) •. Comfortable,.breathable.fabric

8.4.1.3 Design for X (DFX) Methods

Design for Producibility:. We. intend. on. using. commercially. available. solar. cells,. because. flexible. solar. cells. capable. of. providing. the. needed.amounts.of.voltage.and.wattage.for.small,.personal.electron- ics.already.exist..Our.base.jacket.production.will.be.outsourced.for. cost.purposes..We.will.control.the.flow.of.materials.through.efficient. management.of.the.supply.chain..We.will.conduct.testing.to.ascer- tain.the.most.efficient.and.safe.way.to.connect.the.solar.cell.to.the. base.jacket,.which.will.be.our.primary.role.in.production.

Design for Assembleability:.Because.our.design.will.integrate.solar.cells. and.fabrics,.we.will.assemble.the.finished.product.by.hand..The.flex- ibility.and.soft.form.of.the.jacket.will.require.a.human.to.place.the. coils.for.the.heating.component.at.precise.locations..Issues.pertain- ing.to.the.number.of.fasteners.to.stabilize.the.heating.elements.in.the. jacket.and.the.ease.of.these.motions.will.be.the.most.challenging.but. are.capable.of.being.overcome.

202 Design for Six Sigma in Product and Service Development

Pugh’s Concept Selection Concepts

Voice of the Customer

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Warmth + + S S – + +

Body.surface.coverage S + S – – S S

Storage + S – S – + +

iPod/MP3.integration + S – + + S +

Price + S + + + + +

Temperature.regulation.versus.climate + + S S – + +

Temperature.regulation.versus.individual + S – + – + +

Convertible + – – S + + –

Durability – + – S – – S

Adjustability + + S + S + S

Compatibility + + – + – S S

Charging.capability + S S S + + +

Style/design S – – S + S S

Climate.responsiveness + – – S – + S

Total.(+) 12 6 1 6 5 9 7

Total.(S) 2 5 6 8 1 5 7

Total.(–) 1 4 8 1 9 1 1

FIGURE 8.9 Pugh.Concept.Selection.matrix.

203Solar-Heated Jacket—A Design for Six Sigma Case Study

Design for Safety:.Design.for.safety.will.be.paramount.in.our.design.with. the.integration.of.the.solar.cells.and.the.jacket.material..Inherent.in. our. design. will. be. the. treatment. of. the. material. that. will. interface. with. the. coils. of. the. heating. element. with. a. flame-resistant. com- pound..This.coating.will.prevent.the.jacket.from.catching.fire.or.melt- ing.on.the.skin..Our.design.also.incorporates.a.safety.on/off.switch. in.the.lower.pocket.to.quickly.disable.the.transmission.of.heat..This. is.in.addition.to.our.rotary.control.for.normal.heating.regulation.

Design for Serviceability:.The.solar.cells.we.are.intending.on.using.come. with.a.3-year.warranty..However,.upon.entering.into.a.contract.with. the. supplier,. the. warranty. may. be. adjusted. given. the. use. of. them. on.a.jacket,.because.there.will.be.greater.wear.and.tear.on.the.solar. cells.than.the.manufacturer.may.have.intended..Potential.repair.of. broken.solar.cells.should.be.easy.to.accomplish.with.the.connection. point.to.the.jacket.easy.to.access.

8.4.2 Design Phase Case Discussion

. 1.. How.did.you.generate.your.design.concepts?

. 2.. How. did. you. determine. how. your. concepts. compared. using. the. Pugh.Concept.Selection.matrix?

. 3.. How. did. you. derive. the. best. combination. of. your. design. elements. from.each.concept?

• Two solar panels on the shoulders • Right outside pocket contains charger for portable devices • �e left outside pocket contains heating controls • 10 total pockets (6 outside 4 inside)

I Jacket Prototype

FIGURE 8.10 Design.concept.

204 Design for Six Sigma in Product and Service Development

8.5 Optimize Phase Exercises

. 1.. Implement.pilot.process.

. 2.. Assess.process.capabilities.

. 3.. Optimize.design.

8.5.1 Optimize Phase

To.optimize.the.results.of.the.data.we.obtained,.we.decided.to.form.a.small. parameter.diagram.as.shown.in.Figure.8.11..We.quickly.realized.that.solar. energy.cells.would.have.the.greatest.impact.on.the.optimization.of.the.jacket.. We.needed.the.most.valuable.solar.energy.cell.for.our.situation..The.largest. increase.in.efficiency.would.come.from.optimizing.the.solar.cell.because.of. the.high.cost.of.the.solar.cells.and.the.variability.of.capabilities.

The.customer.requirements.showed.that.we.needed.12.V.of.power..This. is.the.power.we.needed.to.warm.the.jacket.and.provide.a.charging.function. for. iPod/MP3. integration. simultaneously.. Our. investigation. of. solar. cells. determined. the. price. of. 12. V. of. power. at. approximately. $80.. Adding. this. solar.cell.would.place.the.price.of.the.jacket.above.the.range.desired.from. the.VOC.

We. decided. to. do. a. comparison. of. the. solar. cells. we. could. locate. on. the. market..We.compared.solar.cells.that.varied.greatly.in.terms.of.power.and. increased.greatly.in.cost.in.terms.of.power..Larger.solar.cells.cost.more.per. voltage. as. voltage. increased.. None. of. the. solar. cells. met. all. of. the. criteria.. However,. after. more. brainstorming. and. group. discussion,. we. decided. to. compare.the.single.solar.cells.against.different.combinations.of.smaller.solar.

Control Factors: 1) Adjustable heat 2) +/– Layers 3) Open/close vents 4) Adjustable straps 5) Capacity of the solar cells

Noise Factors: 1) Environment 2) Activity 3) Material of the jacket 4) Length and intensity of use

Measurement: 1) Power needed for heat 2) Customer’s desired range for heating 1) Minimum of 2 layers 2) Strength of the material 3) Force that the solar panel can withstand

Warm & Comfortable Jacket that Uses

Solar Power

Parameter Diagram

FIGURE 8.11 Parameter.diagram.

205Solar-Heated Jacket—A Design for Six Sigma Case Study

cells.. In. this. fashion,. we. successfully. identified. a. combination. of. smaller. solar.cells.working.as.separate.systems.that.meet.all.the.customer.require- ments.and.kept.the.total.cost.of.the.jacket.in.the.desired.range.

8.5.2 Optimize Phase Case Discussion

. 1.. How.would.you.define.the.design.of.experiment.design.to.use?

. 2.. How.would.you.determine.which.factors.and.levels.were.significant. to.your.design?

. 3.. How. would. you. determine. the. appropriate. number. of. replications. for.your.experiment?

8.6 Validate Phase Activities

. 1.. Validate.process.

. 2.. Assess.performance,.failure.modes,.and.risks.

. 3.. Iterate.design.and.finalize.

8.6.1 Validate Phase

The. verification. of. our. hybrid. super. concept. must. address. two. key. areas. before.it.can.be.delivered.for.full.production:

. 1.. Ensure. that. the. voice. of. the. customer. has. been. met. with. the. final. design.

. 2.. Ensure. the. voice. of. the. process. is. feasible. with. a. high. degree. of. consistency. and. aligns. with. the. expectations. of. the. voice. of. the. customer.

In.order.to.verify.that.our.design.meets.the.voice.of.the.customer,.we.would. propose.to.conduct.a.survey.to.assess.the.strength.with.which.we.met.our. customers’.needs..We.would.try.to.get.all.of.the.same.respondents.who.filled. out.our.initial.survey.to.reply..Shown.in.Figure 8.12.is.a.sample.of.the.areas. we.would.ask.to.rate.on.our.survey.

We. expect. the. results. of. this. survey. to. be. very. positive. with. averages. greater. than. four.. In. addition. to. the. survey,. we. showed. our. prototype. to. a. few.potential.customers.who.are.outdoor.enthusiasts.and.would.be.potential. customers.for.our.jacket..Overall,.the.response.to.the.jacket.was.very.positive. with.one.person.remarking,.“I.would.definitely.buy.this.jacket.if.it.were.avail- able.today!”.Therefore,.we.have.successfully.met.the.voice.of.the.customer.

206 Design for Six Sigma in Product and Service Development

In.the.second.step.of.verification,.we.will.ensure.the.highest.level.of.qual- ity. is. provided. with. the. finished. product.. We. have. a. reliable. and. techno- logically. proficient. supplier. who. can. provide. the. solar. cells. and. a. reliable. supplier.for.the.base.jacket..Our.skills.and.knowledge.in.connecting.the.two. to. provide. an. actively. warming. and. charging. jacket. have. been. established. and.proven.with.a.high.degree.of.success..Our.product.has.been.verified.by. both.the.customer.and.the.process.

8.6.2 Validate Phase Case Discussion

. 1.. How.would.you.identify.potential.failure.modes.of.your.product?

. 2.. How.would.you.identify.potential.risks.of.your.product?

. 3.. How.would.you.assess.the.potential.market.for.your.product?

Topics Rating

(1 = Not Interested at All; 3 = Neutral; 5 = Very Interested)

Can.provide.heat.to.achieve.a.controlled. temperature.up.to.75°F

Has.a.hood.with.heating.capability

Has.retractable.hood

Can.charge.one.small.personal.electronic.in.under. an.hour

Can.hold.iPod/MP3.and.routes.earbuds.within. the.jacket.which.come.out.of.the.collar

Costs.$225

Has.six.pockets.on.the.exterior

Has.four.pockets.on.the.interior

Has.the.ability.to.connect.with.winter.pants

Has.two.underarm.vents.for.temperature.regulation

Has.additional.internal,.optionally.removable. layer.built.in

Is.composed.of.strong.and.durable.material

Composed.of.soft,.breathable.fabric

How.interested.are.you.in.buying.this?

FIGURE 8.12 Survey.questions.

207Solar-Heated Jacket—A Design for Six Sigma Case Study

8.7 Conclusions

The. process. of. developing. a. new. product. cannot. be. undertaken. lightly.. In. order. to. bring. a. new. product. to. market,. there. is. a. considerable. amount. of. risk. involved.. Large. amounts. of. capital. can. be. infused. into. a. project. with. the.expectation.of.positive.results..When.anything.other.than.those.positive. results.occur,.companies.are.left.searching.for.answers.to.what.went.wrong.

DFSS.provides.a.well-conceived.methodology.to.follow.in.order.to.reduce. and.minimize.the.amount.of.risk.in.bringing.a.new.product.to.market..The. cost.associated.with.developing.new.products.can.grow.tremendously.when. work.has.to.be.redone..The.DFSS.methodology.provides.tools.and.best.prac- tices. that. can. be. used. to. limit. these. potential. added. costs.. The. breakdown. of. the. DFSS. methodology. into. phases. allows. for. breaking. up. the. risk. into. increments,.so.if.something.is.not.progressing.with.good.results,.the.project. can.be.put.on.hold.or.scrapped.to.minimize.the.loss..The.gates.are.the.points. at. which. the. incremental. progress. is. evaluated,. and. a. decision. to. continue. pursuing.the.project.can.be.made.

In.our.project,.we.were.able. to.see.this.multiphase.process.in.action..We. came.up.with.our.idea,.brought.it.to.our.customers.to.receive.their.input,.and. were.able.to.develop.a.robust.and.optimized.product.that.met.our.custom- ers’.requirements..We.successfully.used.the.IDDOV.process.to.develop.this. product. for. our. customer.. Throughout. this. whole. process,. we. had. a. clear. vision.of.what.we.wanted.to.accomplish,.and.we.took.a.methodical.approach. to.reaching.it..In.the.end,.we.were.successful.because.we.kept.our.customer. at.the.forefront.of.the.process.and.managed.the.risks.effectively.