Product Design Excellence Black Belt

EngineRoom

Course Map

Total Estimated Hours:  66

SESSION 1: Introduction to Design Excellence 3.9 HOURS

  • Introduction to Design Excellence
  • What is Design Excellence?
  • Design Thinking
  • Closing the Gap
  • Better Aim Through Design
  • Improving Lifecycle Cost
  • DCDOV - The Design Roadmap
  • DCDOV and DMAIC
  • Design Leverage
  • Design Excellence Achievements
  • Introduction to EngineRoom®
  • Project Charter Toolset
  • Project Tracking Toolset
  • Learning and Problem Solving with AI
  • Session Wrap-Up and Skill Check

SESSION 2: Define: Understanding the Voice of the Customer 5.75 HOURS

  • Introduction
  • Obtaining the Voice of The Customer
  • Market Segmentation
  • Understanding Customer Requirements
  • Listening to All the Voices
  • Where to Go For Customer Requirements
  • Conducting Surveys
  • Survey Considerations
  • Surveys - Sampling Frame
  • Structuring Survey Questions
  • Affinity Diagram Toolset
  • CTQC Tree Diagram Toolset
  • Operational Definition Toolset
  • Voice Of The Customer As Specifications
  • Progress Review - Define Phase
  • Session Wrap-Up and Skill Check

SESSION 3: Concept: Divergent Thinking 5.95 HOURS

  • Introduction
  • Quality Function Deployment (QFD) Toolset
  • Metrics
  • The Core Principle of DFSS
  • Process Capability Toolset
  • Benchmarking
  • Beyond Customer Requirements
  • Brainstorming
  • Structured Brainstorming
  • Process Design Principles
  • TRIZ
  • Multi-Voting
  • Pugh Concept Selection Toolset
  • Progress Review - Concept Phase
  • Session Wrap-Up and Skill Check

SESSION 4: Design: Convergent Thinking 5.75 HOURS

  • Introduction
  • Design Development
  • Results By Design
  • Design Scorecard
  • QFD: Building the 3rd House
  • Simple Regression Analysis
  • Multiple Regression Analysis Toolset
  • Error-proofing
  • FMEA Toolset
  • Product and Process Reliability
  • Basic Reliability Calculations
  • Transfer Function Toolset
  • Progress Review - Design Phase
  • Session Wrap-Up and Skill Check

SESSION 5: Introduction to Experimental Design 7.5 HOURS

  • Design of Experiments (DOE) Introduction
  • DOE History
  • DOE Components
  • DOE Principles
  • DOE Purpose
  • DOE Process
  • DOE Guidelines
  • Selecting the Right Design
  • Blocking Variables I
  • Blocking Variables II
  • DOE Simulation: Faster Deliveries
  • Session Wrap-Up and Skill Check

SESSION 6: Executing Designed Experiments 27.45 HOURS

  • Beyond One-Factor Experiments
  • Design of Experiments - Power & Sample Size
  • Two Level Full Factorial Toolset
  • Two Level Fractional Factorial Toolset
  • General Factorial Toolset
  • DOE Simulation: Save The Kingdom
  • DOE Simulation: Better Pizza
  • DOE Simulation: SigmaBrew Coffee
  • Taguchi Methods
  • Session Wrap-Up and Skill Check

SESSION 7: Optimize: Fine-Tuning the Design Solution 8.8 HOURS

  • Introduction
  • Building a Process Model
  • From Process Diagram to Process Model
  • Predicting Process Performance With Simulation
  • Introduction to Discrete Event Simulation - Process Playground
  • Case Study: The Beginning
  • Case Study: Running The Model
  • Case Study: Interpreting Results
  • Optional Process Modeling Tutorials
  • Monte Carlo Toolset
  • Tolerance Design & Optimization Toolset
  • Optimization
  • Continuous Flow Optimization Toolset
  • Design For Lean - Supply Chain Dynamics
  • QFD: Building The 4th House
  • Progress Review - Optimize Phase
  • Session Wrap-Up and Skill Check

SESSION 8: Verify: Launching the New Design 2.6 HOURS

  • Introduction
  • Other Aspects of Verification
  • Process Control Plan
  • Testing a Design
  • Achieving Reliability Through Testing
  • Piloting a Design
  • Launch
  • Ending a Project
  • Progress Review - Verify Phase
  • Session Wrap-Up and Skill Check
  • Course Completion and Feedback