Design and Manufacturing Six Sigma Training

39 Years of Manufacturing Experiences

20 years of Instructor Experiences

Certified Level II Master Black Belt

DMSS uses tough examples

Comprehensive Engineering Training

DMSS offers a unique four-week training program that provides in-depth, real-life examples, hands-on data gathering, and over 192 hours of face-to-face classroom time. The tools and concepts taught will help solve the most challenging problems engineers encounter in their careers. With a class size of up to 24 students, the program offers a diverse range of experiences and valuable networking opportunities in manufacturing and design engineering.

Results

Paint over Zinc Die Cast

The application of paint over zinc die cast can be very challenging. The quality of the casting and the amount of porosity can greatly affect the paint yield. Through a series of over 8 experiments that were run on zinc die casting machines, robotic polish for parting line removal and the paint process itself, paint yields for a specifi

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Coffee Grinder Noise

Paint over Zinc Die Cast

A retro style coffee grinder was created but there were field complaints that some of them were too loud. DOE methods used to investigate and adjusted critical factors led to a 20 dB decrease in the units that were defective as well as creating a prevention method.

Paint Defects

When applying powder coat, if the coating is too thin, it can result in the substrate showing through. On the other hand, too thick of a coating will result in a heavy orange peel look. This is not acceptable for units with Class A finish requirements. The 3D shapes of the parts being coated made it quite difficult for the operators and the automation systems to obtain the optimal coating thickness. Variation studies were done which led to reducing the range of the paint thickness from 1-10 mils, to 2-6 mils. This resulted in less rework and scrap cost as well as an overall material usage reduction and saved over $150,000.

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Noisy Gears

Paint Defects

A trade partner reported that customers were complaining about a high pitch gear noise on some units. They tested a few themselves and found under certain loads, the noise was quite high. They were upset enough to threaten to stop buying the product, which would create a huge financial gap in the plan. Quick work of multiple DOE's gave insight into the tolerance stack up and what the true tolerances in alignment of key gear components should be. Adjustments were made and the high pitch wine was reduced significantly, so much so that the trade partners were quite happy and the sales plan remained in tact, all completed in a 3 week time span.

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Compare the Costs per Hour

DMSS Costs per Student

Other Six Sigma 4 week in person

Typical rates in hotels are about $149 per night and a couple of meals around $30 and for 20 training nights total.

Tuition Room & Board Total

$5,995 $3,580 $9,575

Classroom Instruction Time = ~156 hours

$61.38

Other Six Sigma 4 week in person

Searches show other six sigma type courses for larger cities ;

8 days for $4000 + $960 lodging = $4960/64 hours = $77 per hour (excludes meals)

5 days for $1999 + $695 lodging = $2694/34 hours = $79 per hour (excludes meals)

$78.00

University Training

Other Six Sigma 4 week in person

University Training

Tuition Room Total

Purdue $9,992 $12,820 $22,812

Kettering $48,47 $10,400 $58,870

CalTech $63,402 $20,283 $83,685

Illinois $22,904 $14,522 $37,426

Average $50,698

Classroom Time per year = 425 hours

$119

Curriculum for 4 weeks training

Week 1

Approach and Acquisition, Fundamental Language and Overall Concepts, Critical Thought Process and Product Mapping, Control Chart Methods, Components of Variation, Measurement Systems Studies (MSS), Design and Manufacturing Capability Dependencies, Hands on Studies of Measuring Systems, Review of Projects

Week 2

DOE Basics Planning for Experimentation, Full Factorial Designs, Screening Designs, Experimental Efficiencies, Anova, Noise Strategies for Robust Design, Balsa Wood Airplane Team Project Using DOE Tools to test in real life noisy environments, Project Reviews

Week 3

Expansion of Week 2 Concepts, Repeats, Replicates and Blocking Strategies, Advanced Strategies for the Treatment of Noise, Factor Relationship Diagrams (FRD’s), Data Analysis Methods, Paper Helicopter Hands on Project, Project Reviews

Week 4

Data Presentation Methods Diagnostics for Unreplicated DOE’s The Analysis of Covariance Variation as a Response Part Swap DOE Data Conversion Methodology Taguchi Philosophies compared to Restricted Design Methods Center Point Studies Missing Data Methods 3 level design strategies Project Reviews

Design and Manufacturing Six Sigma Training

39 Years of Manufacturing Experiences

20 years of Instructor Experiences

Certified Level II Master Black Belt

Experience the Joy of Learning with DMSS's in person training

DMSS uses tough examples

Comprehensive Engineering Training

Results

Paint over Zinc Die Cast

Paint over Zinc Die Cast

Paint over Zinc Die Cast

Coffee Grinder Noise

Paint over Zinc Die Cast

Paint over Zinc Die Cast

Paint Defects

Paint Defects

Paint Defects

Noisy Gears

Paint Defects

Paint Defects

Compare the Costs per Hour

DMSS Costs per Student

Other Six Sigma 4 week in person

Other Six Sigma 4 week in person

Other Six Sigma 4 week in person

Other Six Sigma 4 week in person

Other Six Sigma 4 week in person

University Training

Other Six Sigma 4 week in person

University Training

Curriculum for 4 weeks training

Week 1

Week 2

Week 3

Week 4

Events

The Instructor

Darrin Keiser

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