Modelo Design for Six Sigma para desenvolvimento de produtos usinados: uma abordagem para prestadores de serviços de usinagem

Abstract

The tools and strategies applied in the new products development are fundamental for the organizations competitiveness. Since the 1980s, several methods and tools have been created for this process, with Design for Six Sigma (DFSS) being one of the most current methodologies. The present research aims to propose a DFSS model for machined products, aimed at the planning and development of metallic products with medium and high production volume. Large­scale machining processes are offered in vast supply chains (such as automotive), where the manufacture of the machined part must meet the product design, featuring a co­development between customer and supplier. This feature differs product development from conventional models, where design and manufacturing take place under the single management of the same organization. To meet the main objective, and thus fill the research gap on DFSS models for machined parts, the following methodological steps were followed: (a) theoretical survey on the definitions, objectives, phases and respective activities and tools used in the DFSS methodology; (b) proposal of the theoretical structure of DFSS specific for machining; (c) analysis of the statistical relationships that make up the DFSS for machining - Critical to Quality index proposed for early stages of development based on process capability (Cp and Cpk Fuzzy); (d) validation of the proposed model through the critical analysis of specialists who work in the industry with the development of the manufacture of machined parts. As a result of the research, a generic DFSS proposal was obtained, where from this and considering the inputs, operations and outputs of conventional machining processes, and the opinion of 12 professionals in the machining segment and representatives of 4 large groups of companies customers in the machining segment, all located in the Serra do Rio Grande do Sul region, the DFSS model was obtained for machining. To facilitate contact between professionals in the studied segment and the research, the model is presented on a web page. Among the academic and practical contributions that the model presents, the Critical to Quality index for risk analysis in the early stages of development of machined products stands out, which considers historical process data and was created with a view to inserting the DFSS for machining, in machining process plans that interface with cyber physical systems used in industry 4.0.