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1、DFSS Green Belt ProjectPC43t PSU CE projectEngineering: CZ, VY, GY, CLMentor: JZAug, 20172HONEYWELL - CONFIDENTIALBlockers Team memberChiyu Zhong, Vincent Yan, Guo Yisheng, Chen Li Tools Used Opportunity Scope Target to be achievedq Cost down current released PSUq Performance can be same with releas

2、ed product SPECq Customer: Marketing.q Market info: Lower our current PSU costq Thought Mapq SIPOCq QFD-VOCq PMAPq DFMEAq Analysisq Control Planq Localization with new vendor to have lower costq Pass MVT and qualificationsq Customer is satisfied With Products q Cost saving about 100K $ per year Resu

3、lts3HONEYWELL - CONFIDENTIALProject CharterTeam LeadersChiyu ZhongTodays Date8/18/2017Phone Number86ob FunctionEngineerManagerQiao FengLocationSuzhouMentorJanice Zheng ElementDescriptionProject Information0. Project TitleGive a brief project title (five words or less)PC43t PSU CE projec

4、t1. Area of Focus or Function:Manufacturing, Supply Chain Commercialization, Sales, Admin. Process.Scouring; Project Department ; Engineering; Quality2. Problem StatementGive a brief history of the problem project will solve (not the solution).Reduce the cost as much as we can , including engineerin

5、g design, process 3. Benefit to Customers: Who is the customer, what benefit will they see and what are their most critical requirements? Marketing is customer. They hope to cost down the price without performance depression.4. Project Metrics:What improvement is targeted and what will be the impact

6、 on your metrics? Metrics:BaselineGoalEntitlementunitsType the name of the metric under “Metrics” i.e.: Sigma value, defects, yield, capacity, cycle time, closure rate, etc. Ideally, should not be in dollars.Cost down target 34 $Yield80%90%5. Business ImpactWhat is the expected annualized business i

7、mpact? ($)This will bring about 3$ per unit and 100k revenue per year on marketing side.6. Team MembersWho are the full time team members?Chiyu Zhong, Vincent Yan, Guo Yisheng, Chen Li7. Team ResourcesOther resources, especially people occasionally necessary to provide assistanceMonica Miao8. Timing

8、:Estimated time to complete project (months).6months4HONEYWELL - CONFIDENTIALTop Level TMAPT-Map as roadmap that lead us how to do resolve problem !ProcessProblemAnalysisDMAICProblem StatementWhat Is KnownWhat Is UnknownKey Questions to Be AnsweredActions and ToolsDefinelWhat is this project expecte

9、d to solvePSU should be cost downPerformance should be same with released PSUWhat is the real requirement from our customerWhat is the real requirement from our customer?How to cost down the PSUThought mapSIPOCMeasurelHow much can the PSU be cost downlCan the project release on time?Current PSU spec

10、 Current PSU costFeasibility of implement new PSUIs current PSU fully match with its SPECWhat is the expect cost down priceWhat is the real performance of current PSUAnalysislHow to implement the new PSU to meet spec?lHow to optimize the design?Standard Design ProcessDesign lessons of previous desig

11、nNew PSU performance Potential risk of new PSUHow to make a test plan that cover performance test and risks as possibleDFMEAImprovelHow to verify design and performance?Test report for current PSUIs the test items for current PSU enough?Any change on new PSU compared to original one?What are the cha

12、nge on new PSU?Will these changes impact on performance?How to measure themControllWhich inputs and processes should we monitored to maintain quality?How to keep our process remains stable over time? The effect of the improve actionControl plan5HONEYWELL - CONFIDENTIALSIPOCDMAICSIPOC defines the sco

13、pe of the project and customer requirements6HONEYWELL - CONFIDENTIALQFD VOC(Customer Needs)What are the customer needs?What does this need mean to this segment of customers? Why?RankWeightIs satisfying the need a Differentiator or Minimum to Compete?Low costCost down as much as possible based on the

14、 present price 150Minimum to competeHigher reliabilityWithstand long time usage under complex working conditions245Minimum to competeAppearanceAbout the same appearance as original product35Differentiator100DMAICWhat are the customer needs? What is the quantification of the need (i.e., CTQ) What is

15、the customers current baseline? What is the customers next best alternative? How much more or less is required to get paid? What is the quantified value relative to the next best alternative? Low cost BOM cost $12.5 $8.5 $5,000 $100,000Higher reliabilityUL & CE Certification and testsUL & CE

16、 Certification and testsUL & CE Certification and tests $1,000 reliability and market entranceAppearanceNo.No.About the same appearance as original product No.No.Quantified Needs(CTQs)Customer Needs7HONEYWELL - CONFIDENTIALCustomer NeedsFunctional RequirementsTargets and SpecificationsMinimum to

17、 CompeteDifferentiatorLow costCost down as much as possible $8.5XHigher reliability1, Safety Standards2,Pass drop test3, E-cap Lifetime1, CCC,FCC,EAC,RCM,UL & CE Certification 2.survive drops on all 6 faces from a height of 1m onto hard wood3, 15,000 hours at 25.XAppearanceboundary dimension wit

18、hin:Height:35mmWidth:60mmLength:120mmHeight:31.5mmWidth:56mmLength:111mm XDMAIC8HONEYWELL - CONFIDENTIALProcess Map SummaryMarketing RequirementTeam Meeting Receive Marketing requirementC Product ManagerN Marketing requirementN Existing BOM costAnalysis PSU part if have cost down chanceC Product Man

19、gerC Engineer C SourcingN Existing BOM costN Marketing informationSouringAnalysisGot cheap PSUMeet Marketing Requirement Sourcing team work with supplier for lower price Inform the supplier to confirm Got the result meet Marketing requirementC SourcingC SupplierN Update BOM costC Product ManagerN Ne

20、w BOM costAnalysis ME Engineer Analyze whether the mechanical dimensions meet the requirementsVAVANVANVANVAVANVA EE Engineer Analyze whether electronic function meet the requirementsN: dont meet cost down or functionY: Meet cost down and functionVA: valueNVA: no valueNYYYNDMAIC9HONEYWELL - CONFIDENT

21、IALDFMEANext pageAMDIC10HONEYWELL - CONFIDENTIALDFMEAAMDIC11HONEYWELL - CONFIDENTIALCP Capability analysisGuaranteedMDCIA12HONEYWELL - CONFIDENTIALCP Capability analysisGuaranteedMDCIA13HONEYWELL - CONFIDENTIALCP Capability analysisGuaranteedMDCIA14HONEYWELL - CONFIDENTIALCP Capability analysisGuaranteedMDCIA15HONEYWELL - CONFIDENTIALCP Capability analysisGuaranteedMDCIA16HONEYWELL - CONFIDENTIA