Title: Application of Design for Six Sigma to manufacturing process design at Ford PTO

Authors: Rajeev Kalamdani, Faysal Khalaf

Addresses: PTO Manufacturing Engineering, Ford Motor Company, 21500, Oakwood Boulevard, Dearborn, MI 48124, USA. ' Ford Motor Company, One American Road, Dearborn, MI 48124, USA

Abstract: Design for Six Sigma (DFSS) is generally used in the context of either product design or business process design. In the product design optimisation using the DFSS approach, the interaction with the manufacturing process is modelled as noise. The purpose of this paper is to highlight the area of manufacturing process DFSS by showcasing some recent successes at Ford in assembly, heat treatment, grinding and casting. These types of projects were undertaken at the manufacturing process design phase with the objective of minimising the variability of finished product characteristics due to manufacturing variability. Understanding the physics involved in the transformation from raw material to finished products was a necessary component that distinguishes these projects from DMAIC projects.

Keywords: manufacturing process design; design for six sigma; DFSS; direct acting mechanical bucket; DAMB tappet assembly; crankshaft induction hardening; camshaft grinding; casting simulation; product design optimisation; Ford Motor Company; manufacturing variability.

DOI: 10.1504/IJPD.2006.009917

International Journal of Product Development, 2006 Vol.3 No.3/4, pp.369 - 387

Published online: 01 Jun 2006 *

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