Utilizing Kaizen process and DFSS methodology for new product development. Issue 3 (6th March 2017)

• Record Type: Journal Article
• Authors: Awad, Mahmoud; Shanshal, Yassir A.
• Is Part Of: International journal of quality & reliability management. Volume 34:Issue 3(2017)
• Page Start: 378
• Page End: 394
• Publication Date: 2017-03-06
• Subjects: Kaizen -- Design for Six Sigma -- Design of experiments -- Oil consumption -- SHAININ; Quality control -- Periodicals; 658.562
• DOI: 10.1108/IJQRM-09-2014-0139
• Languages: English
• ISSNs: 0265-671X

Abstract

Abstract : Purpose: The purpose of this paper is to propose a new framework for early design stage utilizing the benefits of Kaizen events, and Design for Six Sigma (DFSS) methodology. To gain a better understanding of the proposed method, a case study of a diesel engine development was presented where the proposed methodology was followed. Design/methodology/approach: This paper proposes a hybrid Kaizen DFSS methodology consisting of four Kaizen milestone events with pre-work preceding these events. The events are in line with the four phases of DFSS methodology (define, characterize, optimize, and verify). Findings: In order for the proposed method to succeed, few key enablers should be available such as management buy-in and support, effective resources utilization, and proper planning. However, this methodology should be utilized for key projects where criticality is high and deadlines are nearby. Practical implications: As proved by two projects, one of them is presented in this paper; the use of the proposed methodology is effective and can bring significant positive changes to an organization. Originality/value: Although Kaizen is an old and well-known process, it is to the best of the author's knowledge that Kaizen has not been utilized in the early design stages of new product development projects. In this paper, a hybrid methodology combining traditional DFSS systematic approach conducted using Kaizen improvement events is proposed and supported by a real-life case study.