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CARTA DE ACEPTACIÓN
JESÚS GERARDO CRUZ ÁLVAREZ BERENICE MÉNDEZ SÁENZ
P R E S E N T E
En nombre del cuerpo arbitral, tengo el agrado de comunicarle que el trabajo RIICO-4702
Lean Design For Six Sigma: an Integrated Approach to Achieving Product Reliability and
Low-Cost Manufacturing , ha sido aceptado para ser presentado como ponencia en el VI
Congreso de la Red Internacional de Investigadores en Competitividad, razón por la cual le
enviamos una cordial felicitación.
De conformidad con la convocatoria, dispondrá de 15 minutos para la exposición de su
trabajo, seguidos de una sesión de 15 minutos de preguntas y respuestas así como las
conclusiones finales; por consiguiente, le recordamos que oralmente solo podrá exponer
lo esencial de la versión escrita de su ponencia. La fecha y horario de su presentación le
será comunicado posteriormente.
Para la elaboración de las memorias del congreso, requerimos de su autorización para la
publicación de su ponencia, por lo que le solicitamos llenar y firmar el formato adjunto.
Agradeciendo su participación, que confiamos será benéfica tanto para usted como para
nuestro congreso, aprovecho la ocasión para enviarle un cordial saludo.
A t e n t a m e n t e
Zapopan, Jalisco; Octubre 02 de 2012
DR. JOSÉ SÁNCHEZ GUTIÉRREZ
PRESIDENTE DE LA RED INTERNACIONAL DE
INVESTIGADORES EN COMPETITIVIDAD
Cuerpo Académico Consolidado UDG-CA-484
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CO-0607
Competitiveness And Social Responsibility In The Rubber Industry
Ugalde Sánchez Karen
José Sánchez Gutiérrez
CO-0408
El uso de las tecnologías de información para mejorar la
competitividad en el cálculo de las finanzas empresariales.
CO-0308
Elaboración Del Modelo Estimativo Para El Comportamiento De Cemex
En El Mercado Accionario Mexicano
15
:00
A 1
7:0
0 H
RS
CO-0506
Intellectual Capital For The Competitivenes In The Furniture Industry
In Guadalajara, Mexico
Gaxiola Villaseñor Mercedes Elisa
José Sánchez Gutiérrez
Hernández Correa Tomás Celis Flores Ilse
Chávez Capó Anselmo Salvador Ramírez Bonilla María Elena
Chávez Morales Ubaldo
Niño Castillo Jacob Elías
Niño Gutiérrez Naú
Niño Castillo Isaías Naú
Mayorga Salamanca Paola Irene
Sánchez Gutiérrez José
VI CONGRESO DE LA RED INTERNACIONAL DE INVESTIGADORES EN COMPETITIVIDAD
1ER COLOQUIO DE ESTUDIANTES - SALÓN VALENCIAMIÉRCOLES 14 DE NOVIEMBRE DE 2012
CO-0104
Evolución espacio-temporal de modelos turístico-económicos de
Acapulco, Guerrero, México
CO-0207 Efectos de la Mercadotecnia y Responsabilidad Social en la
Competitividad de las Pymes Manufactureras de la Zona
Metropolitana de Guadalajara
Page 3
VI CONGRESO DE LA RED INTERNACIONAL DE INVESTIGADORES EN COMPETITIVIDAD
PONENCIAS MAGISTRALES - SALÓN SEVILLA - 09:00 A 11:30 HRSDR. FERNANDO ÚBEDA MELLINALIC. ALEJANDRO MALACARA ORTIZ DE MONTELLANO
La Propiedad Intelectual en México Factores determinantes y efectos de la Inversión Directa Exterior de la Economía Española
JUEVES 15 DE NOVIEMBRE
Salón Valencia Salón Salamanca Salón Alicante
RIICO-3202 La Relación de la Gestión de las
Cadenas de Suministro con los Procesos de
Producción para la Competitividad de la Pyme de
AguascalientesAguilera Enriquez Luis
Hernández Castorena Octavio
Lopez Torres Gabriela Citlalli
Moderador:Badillo Gaona Manuela
Comentarista:Morales Alquicira Andrés
Moderador:Acevedo Valerio Víctor
Antonio
PRESENTACIÓN DE TRABAJOS DE INVESTIGACIÓN - 12:00 A 14:00 HRSSalón Sevilla Salón Madrid Salón Barcelona
Competitividad Global Comp. Ind. Y Asuntos Tec. Vent. Comp. Y Des. Eco Educación y Competitividad Gestión del Conocimiento Comp. y Des. Fin
Moderador: Cárdenas Villalpando
Alfredo Salvador
Comentarista: Martínez Serna María
del Carmen
RIICO-22701 El Mueble Mexicano Y Su
Competitividad Versus El Asiático: Percepción
Comprador Internacional
Moderador: Moreno Zacarías Hugo
Martín Moderador: López Ortega Eugenio Moderador: Aguilasocho Montoya Dora
Comentarista: Rendón Trejo Araceli Comentarista: Montero Delgado Nancy
Imelda
Comentarista: Vargas Barraza Juan
AntonioComentarista: Socorro Diaz Nieto
Meza Juárez Fernando José
RIICO-16204 Investigación, Desarrollo E
Innovación En Alemania: Una Aportación A
México
RIICO-4305 Educación y Competitividad como
Elementos Proveedores de Desarrollo
Medina Romero Miguel Ángel
Flores Negrete Guadalupe Laura Zamora Mendoza Juan Manuel
Robles Estrada Celestino
RIICO-7506 El capital relacional como factor
determinante de la absorción de conocimiento
externo para la innovación. Un estudio empírico
l i d i f é i iCanto Valencia Herlinda
Vera Arenas Estela
Rivero Villar María Josefina
Madrigal Torres Berta Ermila
Bautista Evelio Gerónimo
Ruiz García Rodrigo
RIICO-4702 Lean Design For Six Sigma: an
Integrated Approach to Achieving Product
Reliability and Low-Cost Manufacturing.
Cruz Álvarez Jesus Gerardo
Méndez Sáenz Berenice
RIICO-0201 Análisis del impacto de la gestión de
conocimiento y el capital intelectual sobre la
competitividad de las Pymes manufactureras de
la región occidente de México
Vázquez Ávila Guillermo
Hernández Cotón Silvio Genaro
Núñez Moreno Tania Emma
RIICO-21001 Corea Del Sur Y México: Política
Económica Para La Competitividad Internacional
Bendreff Desilus
RIICO-10401 Imagen De Responsabilidad Social:
Factores Competitivos Que Influyen En El
Comportamiento Del Consumidor
Pacheco Ornelas Ma. Cristina
RIICO-6302 La percepción acerca de la privacidad
y seguridad en el social commerce en México: Un
estudio exploratorio
Alvarado Benitez Laura Margarita
García Medina Gabriel
RIICO-0104 Gobierno local y capitales
transnacionales. El caso del Polo Petroquímico de
Bahía Blanca (Argentina)
RIICO-5305 El Análisis De Las Percepciones Y
Expectativas De Los Alumnos De Doctorado A
Distancia De La Universidad Marista De
G d l jBrunet Icart Ignasi Cuevas Shiguematsu Carlos Yoshio
Santamaría Velasco Carlos Alberto Pelayo Maciel Jorge
Pérez Torres Griselda
RIICO-1004 Factores clave para la sobrevivencia
de una Empresa Familiar a varias generaciones
RIICO-5405 Similitudes en la Innovación de los
Sistemas de Formación Profesional en Países
como México, Alemania y Hungría.
Gutiérrez González Leonor
RIICO-6104 Modelo De Negocios, Necesidades
Del Cliente Y Gestión De La Innovación:
Propuesta De Proceso Conceptual Para La Mejora
Competitiva
RIICO-6405 El Desarrollo De Estrategias De
Promoción Diferenciadas En Los Programas
Educativos, El Caso De UDGVirtual
Mejía Trejo Juan Díaz Pérez Cristina
RIICO-21402 Modelo de satisfacción del cliente
en la industria restaurantera de la Zona
Metropolitana de Guadalajara
Espinoza Mercado Oscar Alejandro
Valenzo Jiménez Marco Alberto
Galeana Figueroa Evaristo
Martínez Arroyo Jaime Apolinar
González Álvarez Tonia Dafné Zúñiga Cortez Juan Hermilo
RIICO-9202 Logistics competitiveness Mexico vs
BRICS 2012
RIICO-2906 El Conocimiento de Mercadotecnia
como herramienta competitiva en las empresas
de manufactura contratada de la industria
Ortiz Barrera Manuel Alfredo
Sánchez Gutiérrez José
Vázquez Ávila Guillermo
RIICO-3506 Tecnología de Información para
Impulsar el Capital Intelectual en una Universidad
Privada del Estado de Guanajuato
Villagómez Torres Maya Gicela
González Uribe Elsa Georgina
RIICO-20804 La Competitividad En El Estado De
Guanajuato: Una Visión A Través De Los
Indicadores Del Comercio
RIICO-7905 Innovando PyMEs a través de la
vinculación con el enfoque de la Triple Hélice
Ruiz Diaz Fernando M Gómez Ortíz Rosa Amalia
Saldaña Contreras Yolanda Millán Gómez Paola Pilar
Mancha Villareal Mónica
RIICO-8908 El análisis financiero como
proceso para el desarrollo y la
competitividad de las Pequeñas y Medianas
( ) d l ió d l Zúñiga Cortez Juan Hermilo
González Guajardo Emilio
Gutiérrez González Leonor
RIICO-1104 De Empresa Familiar A Familias
De Empresarios: Propuesta Para Preservar
El Patrimonio Empresarial Y Legado Familiar
Saldaña Contreras Yolanda
Verdugo Tapial Leticia
Parada Ruiz Elva
RIICO-4508 Variables de la Responsabilidad
Social Empresarial y su influencia en el
desempeño financiero de las empresas.
Méndez Sáenz Alma Berenice
Cruz Álvarez Jesús Gerardo
RIICO-8308 La arquitectura de las finanzas
personales de la población
económicamente activa de Mérida,
á i d i i Duarte Cáceres Laura
ll Bojorquez Zapata Martha Isabel
Rosado Muñoz Yolanda Leonor
RIICO-12906 Desarrollo Del Índice De Utilidad De
La Innovación Para El Diagnóstico De Las Pymes
En El Estado De Hidalgo
Corona Armenta José Ramón
Montaño Arango Óscar
Ortega Reyes Antonio Oswaldo
RIICO-14506
La Gestión Del Conocimiento En Las Pequeñas Y
Medianas Empresas (Pymes): Una Estategia De
i i id dOchoa Ruiz Josefina
Romero González Rosa María
Morgan Beltrán Josefina
COMIDA - 14:00 A 15:10 HRS
De la Garza Cienfuegos Sandra P.
Mancha Villareal Mónica
RIICO-10208 Success Factors of a Quality
Model Award
Cruz Álvarez Jesús Gerardo
Méndez Sáenz Alma Berenice
Sánchez Gutiérrez José Guerrero Muñoz Juan Carlos
RIICO-9601 La Competitividad Empresarial, Suconcepción
Y Condicionantes: Estudio Cualitativo Con Expertos Y
Empresarios
López López Paula Andrea
Cabrera Martínez Alejandra
Yebra Molina Vianey Celina González Guajardo Emilio
Colín Salgado Mónica
Page 4
PRESENTACIÓN DE TRABAJOS DE INVESTIGACIÓN - 15:15 A 18:00 HRS
Salón Madrid Salón Barcelona Salón Valencia Salón Salamanca Salón AlicanteSalón Sevilla
Moderador: Flores Galavíz José Luis
Comentarista: Galeana Figueroa Evaristo Comentarista: Torres Rivera Alma Delia Comentarista: Vázquez Ávila Guillermo Comentarista: Aguilera Enríquez Luis Comentarista: Gómez Chiñas CarlosComentarista: Martínez Arroyo Jaime
Apolinar
Comp. Ind. Asun. Tec Vent. Comp. Y Des. Eco Educación y Compt Gestión del Conocimiento Comp. Y Des. Fin
Moderador: Zamora Mendoza Juan
Manuel Moderador: González Ortiz Jorge Horacio Moderador: Gómez Ortíz Rosa Amalia Moderador:Santos Virgen Jesús Martín
Moderador: Alfaro Calderón Gerardo
Gabriel
Competitividad Global
Bojórquez Carrillo Ana Laura García Velázquez Ma. del Rosario Zápari Romero Gloria Yaneth Infante Jiménez Zoe T. Morales González María Antonia Gaytán Cortés Juan
RIICO-19704 El uso del derecho de acceso a la
información pública como herramienta
para alcanzar la competitividad de la empresa
RIICO-9902 La relevancia de la innovación
tecnológica en la competitividad empresarial
RIICO-25004 El incremento de la competitividad
en las PyMEs manufactureras de Guadalajara a
través del desarrollo del capital intelectual
RIICO-6005 Redes de Innovación de la Zarzamora
en Michoacán
RIICO-17906 Calidad En El Servicio En Los Dos
Principales Establecimientos Comerciales De
Dzilam González, Yucatán
RIICO-16108 El desempeño financiero en el
sector de las pymes manufactureras de la
zona metropolitana de Guadalajara.
Carcaño Loeza Álvaro Hernández Callejas Yolanda Ornelas Alma Angelina Ortega Gómez Priscila Castillo Herrera Francisco Javier Mejía Trejo Juan
Villasuso Pino Víctor Manuel Navarrete Zorrilla Dolores Margarita Ortiz Barrera Manuel Alfredo Bonales Valencia Joel Madero Llanes Jorge Emeterio Vizcaíno Antonio de Jesús
Coria Páez Ana Lilia Ortega Moreno Irma Cecilia Muñoz Zapata Daniel Chavarría López Leticia Refugio Chávez Capó Anselmo Salvador Briceño Santacruz Ma. de los
l
RIICO-16501 Las capacidades de mercadotecnia
como un factor que incide en la competitividad
de los productores de flores en México
RIICO-17702 La relación competitividad-
innovación-tecnología en microempresas: dos
casos
RIICO-6904 Imagen Inducida como Estrategia de
Desarrollo Local: Propuesta para la Avenida
Revolucion en Tijuana, B.C.»
RIICO-6605 La integración de la inteligencia
emocional como estrategia competitiva para la
formación de estudiantes de licenciatura
RIICO-18006 Determinación de los pasivos
intangibles de las empresas Televisa y Wal-mart
en la categoría de información, durante marzo-
d l 20 2
RIICO-17108 CAPACIDAD GENERADORA DE
UTILIDADES.
Un Modelo de valor-competitividad como
i d l ’ j l
Ortega Moreno Irma Cecilia Galván León Jorge De la Torre Hidalgo Tito Livio Varela Castro Werner Horacio
Andrade Vallejo María Antonieta Cruz Reyes María Angélica Montero Delgado Nancy Trujillo Flores Maricela Rivero Villar María Josefina Guzmán Cedillo Rosa María
Colín Salgado Mónica Agudelo Orrego Beatriz Eugenia González Alvarado Tania Elena Yarto Chávez Manuel Antonio Montaño Arango Óscar Rodales Trujillo Ma. Hilda
RIICO-17201 Marketing factor de competitividad:
sector textil de Guanajuato
RIICO-13501 Procesos De Gestión Del Talento
Humano Y Su Articulación Con La Estrategia
Organizacional
l ll l
RIICO-7204 Articulación con la localidad y
competitividad internacional: análisis de un caso
atípico
RIICO-8005 La arquitectura financiera en las
empresas de cartón corrugado en México y la
contribución de las IES para la competitividad del
RIICO-19906 El Conocimiento Estratégico Como
Herramienta Competitiva Para Fortalecer La
Industria Del Estado De Hidalgo
RIICO-18108 Los Sistemas de Información
en la Administración Pública para Elevar la
Competitividad Institucional.
Estrada Rodríguez Salvador Flores Cervantes Claudia Hernández Gress Eva S.
Segura Rodríguez Ana Jackelinne Steggemann Michael Badillo Gaona Manuela Corona Armenta José Ramón Chávez Zamora Mario
Estrada Garza Sasha Ivonne Ramirez Elbar Palos Delgadillo Humberto Urzúa López José de Jesús Fierro Moreno Erendira Ojeda Pérez Fabián
RIICO-1501 El desvanecimiento de la Industria
Pulquera Mexicana: Estrategias de marketing
para incrementar el consumo de pulque en
d l
CO-20003 Consorcios Exportadores LocRIICO-7704 La Gestión Social para el Manejo
Sustentable de los Recursos Hidrícos de la Cuenca
del Ahogado en la Región del Río Santiago, Jalisco
RIICO-9505 Las funciones actividades y tareas,
enfoque perceptual por los alumnos de la
licenciatura de Mercadotecnia del CUCEA (U. de
)
RIICO-24606 La Innovación Organizativa Y La
Mediación De La Gestión Del Conocimiento
RIICO-19508 Implementación De
Estratategias Financieras, Fiscales Y
Administrativas En Las Gasolineras Del
á l
Vizcaino Antonio de Jesús Quintana Meza Meztli Alcaraz Marín Adriana Cernas Ortiz Daniel Arturo Espíritu Olmos Roberto
Vargas Barraza Juan Antonio Cajigas Romero Margot Grave Prado Jesús Héctor Muñoz Fajardo Martha Filomena Mercado Salgado Patricia Priego Huertas Héctor
De la Garza Cienfuegos Sandra
Bonales Valencia Joel González Guajardo Emilio Palos Delgadillo Humberto Robichaud Yves Rosado Muñoz Yolanda Leonor
RIICO-2001 Propuesta para el desarrollo turístico una
oportunidad de negocio, Pymes y la comunidad en general
del municipio de Cuatrociénegas, Coahuila.
RIICO-0803 Eficiencia de las pymes exportadoras
del estado de Michoacán
RIICO-10804 El Impacto Familiar En La
Sustentabilidad Y Tercera Generación De
Mipymes En El Municipio De Monclova Coahuila,
é i 20 2
RIICO-10305 Factores Clave Del Clima Laboral
Que Influyen En Los Resultados Y Productividad
Del Posgrado Cucea De La Universidad De
G d l j
RIICO-26205 Female Entrepreneurs’ Motives And
Sme’s Growth:
An International Study
RIICO-20108 Estudio Descriptivo De Las
Pymes Yucatecas Beneficiadas Con Créditos
Gubernamentales
Mancha Villarreal Mónica Olivo Méndez Víctor Hugo Gutiérrez González Leonor Sánchez Lozano Lizette Areli McGraw Egbert Herrera Zapata Renán
Ruiz Díaz Fernando M. Aguirre Ochoa Jerjes I. Zúñiga Cortez Juan Hermilo Márquez Enríquez Sandra Margarita Cachon Jean Charles Duarte Cáceres Laura
ll
Bojórquez Gutiérrez Alberto Díaz Nieto Elia Socorro Cruz Reyes María Angélica Rojas Vélez Begoña Ceja Oseguera Salvador Chávez Nieto Dinorah Joyce
RIICO-15501 Dirección y posición de las Pymes en su
ambiente competitivo. Caso Sinaloa RIICO-2703 Modelo de Gestión del Clima
Organizacional y Liderazgos Enfocado a la
Productividad Caso en Empresa del Estado de
Q é
RIICO-12604 La identificación de perfiles
estratégicos en la PYME, ventaja que propicia
competitividad
RIICO-12105 Utilización y apropiación de
celulares como dispositivos móviles en la
educación en ambientes de competitividad.
di í i
RIICO-9005 Análisis de las competencias para el
emprendedurismo que se desarrollan en los
cursos presenciales de las licenciaturas del área
d i
RIICO-21308 El Costo De Capital Promedio
Ponderado Como Indicador De Una Ventaja
Competitiva Financiera
Pérez Bravo Julia Cruz Reyes Bricio Vera Arenas Estela Ramírez Murillo Laura Mayela
Bojórquez Gutiérrez Fernando Morgan Beltrán Josefina Coria Páez Ana Lilia Galindo Ramírez José Luis De la Torre Hidalgo Tito Livio Aguilera Aguilera José Rafael
Varela Alemán Omar G. Coronado Quintana José Ángel Olivares Contreras Rodrigo Alejandro Acevedo Valerio Víctor Antonio Flores Preciado Juan
RIICO-17601 Requerimiento de proveeduría de
las grandes empresas hacia las PYMES en el
Estado de San Luis Potosí.
RIICO-13103 Liderazgo En Un Centro De Atención
Telefónica De Una Empresa Comercializadora Y
Distribuidora De Energía Eléctrica En El Noroeste
é
RIICO-13204 Influencia Del Género En La
Selección De Estrategias Corporativas
RIICO-12305 El Impacto Del Aprendizaje
Significativo A Partir Del Enfoque De
Competencias: Caso Aplicado En Educación
RIICO-3304 Desarrollo Regional, Migración y Uso
Productivo de los Remesólares en Michoacán
RIICO-21708 Estrategias Financieras En Las
Empresas Familiares En Colima
18:00 Hrs - Reunión de Proyectos en Red- en Salón Sevilla
Hernández García Patricia Cerecer Castro Bayardo Flores Novelo Anel Reyes Fong Teodoro
Borjas García Edgardo Saavedra Cota María Elena Vaillant Yancy Torres Valdivieso Eugenia Acevedo Nieto Carlos Antonio Flores Félix Rogelio
Page 5
• Área del conocimiento: Competitividad en la industria y asuntos tecnológicos
• Temática: Lean Design For Six Sigma: an Integrated Approach to Achieving
Product Reliability and Low-Cost Manufacturing.
• Nombre de autores:
o Dr. Jesus Gerardo Cruz Alvarez
o Berenice Méndez Sáenz (Candidata a Doctora)
• Institución a la que se representa: Facultad de Contaduría Pública y
Administración de la Universidad Autónoma de Nuevo León
• Domicilio: Avenida Universidad s/n, Cd. Universitaria, San Nicolás de los Garza
• Numero de teléfono: (81) 1340 – 4430 y (81) 8329 - 4080.
• Fax: (81) 8376 - 7025
• Correo electrónico: [email protected]
• Dirección para correspondencia: Frida Kahlo 4416. Priv. Portal de Cumbres,
C.P. 64346, Monterrey, N.L.
Page 6
Lean Design For Six Sigma: an Integrated Approach to Achieving Product Reliability and Low-Cost
Manufacturing.
Abstract
The aim of this study is to discuss new product development based on a traditional stage-gate
process and to examine how new product development [NPD] tools, such as lean design for
Six Sigma, can accelerate the achievement of the main goals of NPD: reliable product
quality, cost-effective implementation, and desired time-to-market. These new tools must be
incorporated into a new approach to NPD based on the Advanced Product and Quality
Planning methodology.
Key words: Design for Six Sigma, Analysis of variance (ANOVA), Industrial
experimentation, Robust design, DMAIC.
Resumen
El objetivo de la presente investigación es la promoción de una discusión teórica y practica
sobre el enfoque tradicional de lanzamiento de nuevos productos bajo la metodología por
fases. Una revisión a profundidad cómo las nuevas herramientas del desarrollo de nuevos
productos en lo particular el diseño para seis sigma puede acelerar el tiempo de respuesta al
mercado de forma exitosa y a una relación atractiva de costo – beneficio. Las nuevas
herramientas pueden ser incorporadas dentro de la estrategia de desarrollo de nuevos
productos bajo el enfoque de planeación avanzada de la calidad de nuevos productos.
Palabras clave: Diseño para seis sigma, análisis de varianza, experimentación industrial,
diseño robusto, metodología DMAIC.
Page 7
Introduction
In today’s market and business environment, new product development is one of the key
operations of a firm. Evolving market dynamics require new products to be innovative and
competitively priced and to use sustainable technologies; meanwhile, firms require NPD to
be cost-effective and to have an optimal time-to-market cycle.
NPD performance from a global perspective is most easily measured as the number of patents
obtained per country and the amount of investment in R&D (research and development).
(OCDE, 2012), the top ten economies in terms of the number of patents granted are almost
identical to the top ten in terms of R&D investment (see Figs. 1 and 2).
Figure No. 1. New Granted Patents (OCDE, 2012).
0
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200
250
300
350
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Figure No. 2. R&D Spending (OCDE, 2012).
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NPD follows a traditional approach that begins with identifying a new idea or concept for a
new product and continues with design, industrialization, testing, validation and sales.
However, due to increasing market competitiveness, firms must incorporate advanced
processes for new product development, such as APQP (advanced product quality planning)
and LDFSS (Lean Design for Six Sigma).
Methodology
This research paper is based on the theoretical background presented in peer-reviewed
scientific research papers during the period 1990–2012. In the second section of this study,
the author provides examples of the proposed tools and of advanced techniques to show
evidence that validates the hypothesis.
New product development framework
In terms of its function and process, NPD represent a key strategic area for every firm. NPD
is related to business intelligence; R&D, marketing, product phase in and phase out strategy,
and innovation, among other capabilities (see Fig. 3).
Figure No. 3. NPD Conceptual Diagram (by Cruz, J.).
NDP
(New Product
Development )
Business Intelligence
Market KPI (Key Process Indicators )
Innovation
Product Competitive StrategyProduct Sustainability
R &D
(Research and Development )
LDFSS
(Lean Design for Six Sigma )
EOL
(End of Life Strategy )
Page 9
Model development and hypothesis
The main goal of this study is to present practical evidence that LDFSS can be introduced
into the NPD process to accelerate the achievement of its primary goals: reliable product
quality and low-cost manufacturing (see Fig. 4).
Figure No. 4. Hypothesis Framework (by Cruz, J.).
Theoretical background
Some organizations have reported NPD to be one of the top three that have received the
most attention, as proposed by Goetsch, D.L. and Davis, S.B. (2010), and have suggested
that its success depends on design expertise and research and development capabilities in
addition to the necessary input from different functional areas, as mentioned by Afonso, P.,
et al. (2008), Handfield, R.B., et al. (2008) and Plambeck, N. (2011). Typically, different
functional areas work simultaneously during this process.
In the early stages of new product development, a cross-functional team must provide
feedback on the design and help the firm to achieve a cross-validated industrial design. The
key parties involved in this step include suppliers, manufacturing, and process, quality and
design engineers, as discussed by Rasli Muslimen, A.S.Z.A., et al. (2012).
Communication between R&D and marketing has a highly significant effect on the final
conceptual design, as does the engineers’ expertise in finalizing the industrial design, as
confirmed in a previous study by Chang, H.C. (2011) that examined 138 high-technology
Taiwanese firms and found interaction between NPD teams. Similar theories and discussion
are presented by Griffin, J. (1996), Henderson, S., et al. (2005), and Fernandez, B.I. (2001).
There are some theoretical studies that describes the relationships and business synergy
associated with well-designed, customer-oriented products: Kano, N. (2001), Su, C. (2006),
Fornell, C. (1987), and Cristiano, J., et al. (2000). Firms can also use web-based technology
as a powerful tool that can bring them closer to customers and determine their perceptions
(both positive and negative) of a product. Pioneering web-based technology focused on
consumer perceptions was developed by Park, Y. (2011).
NPD
LDFSS
Product Quality
Reliability and Low Cost
Manufacturing + =
Page 10
New product development requires customer input, and this knowledge can be extracted
and analyzed using a variety of marketing and customer-driven tools, such as QFD (Voice
of Customer and House of Quality) and customer profile studies.
New product development should be considered a powerful strategy for meeting customer
preferences through customer-focused products. QFD (Quality Function Deployment) is a
customer-driven approach that transforms customer expectations into engineering
requirements and manufacturing process parameters. According to Pang, J., et al. [16],
QFD is extremely important during the product design stage. Working papers and empirical
research proving the effectiveness of QFD during a design gate include Govindalruri, S.M,
Cho, B.R. (2007), Freiesleben, J. (2010) and Sharma, J.r., Rawani, A.M. (2007).
As indicated by Chan, S.L., et al. (2011), new product development includes four major
steps: 1) Opportunity identification, 2) Conceptualization, 3) Product design and
development, and 4) Product launch and commercialization. However, this approach is not
aligned with new business dynamics (see Fig. 5). The goal of this working paper is to
propose that the APQP (Advanced Product Quality Planning) methodology allows a firm to
face design issues at an early stage using different tools and lean design for six sigma. This
approach should make it possible to ensure better design concepts and industrialization
while combining research and development with product and process reliability to create a
lean product design process (see Fig. 6).
Product design and lean product design are two different concepts. Product design is a
traditional approach to new product development that involves obtaining an idea, making
an industrial design, validating the design and launching the product. In contrast, lean
design focuses on reducing the overall product development cost and time to design as well
as ensuring a cost effective product launch, as outlined by Azharul, K., et al. (2011).
Page 11
Figure No. 5. Stage-Gate Process (Cooper, R.G., 2001).
Idea Generator
Figure No. 6. Advanced Product Quality Planning (APQP, 2007).
Previous discussions by Ulrich, K. (1995), Karim, M.A., et al. (2009), and Cloke, B. (2000)
focus on the idea that organizations compete with regard to product innovation, time-to-
market, and research and development. To remain on the cutting edge, companies must
emphasize quality, cost, productivity and bringing the product to the market. Research and
development, in addition to a focus on reliable product quality, enables lean product design
development. According to Cloke, B. (2000), any type of investment made during the
design stage will be lower than any type of improvement made during the product
manufacturing phase.
Marketing
& Business
Case
Process Design
Product and Process Selection
Planning
Product Design
Innovation
Sustainability Customer
Scoping Business Case
& Plan
Develop ment
Testing and validation
Launch
Page 12
Research and development, product quality and process reliability are not the only factors
in new product development; speed to market, product quality and cost are alternative
priorities. Recent empirical research by Rodriguez, P., et al. (2005) revealed that consumers
are more influenced by product quality than speed to market; these results are consistent
with previous research by Barker, W.E., and Sinkula, J.M. (2008), and Grinstein, A. (2005).
This customer perspective demands more from organizations, which must conceptualize,
design and launch high-quality products with better process manufacturing reliability than
those of their competitors, according to Kirca, A. and Jayachandran, S., et al. (1995) and
Atuahene, K. (2011).
According to Heinzen, M. and Höflinge, N. (2010) the competitiveness of successful firms
is based on their ability to balance product quality and innovation with cost-effective NPD
and reduced time-to-market cycle time. To achieve cost-effective NPD and a short time-to-
market, firms must implement concurrent LPD (Lean Product Design) strategies.
According to Schulze, A., et al. (2010), Womack, J., & Jones, D. (1996) and Walton, M.
(1999), LPD can be understood as integrating the following steps: 1) specifying customer
value; 2) identifying the value stream; 3) making the value flow; 4) letting the customer
pull; and 5) ensuring continuous improvement.
Competing organizations facing these difficult business dynamics must identify their
technological and human capabilities to determine and achieve key market objectives:
increasing end-product quality and shortening the time-to-market cycle. Heinzen, M. and
Höflinge, N. (2011) found that on-the-job training contributes significantly to the efficiency
of NPD processes and enhances the motivation and skills of the new development team.
Another approach to the NPD process is explained by Grunert, K., et al. (2011), who
suggested that NPD involves key process activities such as 1) consumer insight into the
new product development process; 2) quality perception as a focal construct; 3) market
opportunities and idea generation; 4) consumer acceptance of technology; 5) screening,
concept development and concept testing; and 6) prototype testing. However, this approach
does not consider process design or product and process validation to be part of an
advanced focus on product quality planning.
NPD is mainly driven by cost-effective implementation and profitability. However, for
optimal results, NPD must balance economics, design and ecology. The new eco-design
approach impacts the overall concept of product design and the selection of manufacturing
processes, as highlighted by Grunert, K., et al. (2011).
An alternative to the traditional approach to NDP that is presented by Baril, C., et al. (2011)
and Breyfogle, F. (1999) employs the concept of Six Sigma as a quality philosophy that
involves the use of statistical tools within a structured methodology to obtain the
knowledge needed to out-compete other firms in terms of the quality, time-to-market and
price of their products and services. In addition to the Six Sigma approach, Baril, C., et al.
Page 13
(2011) presents the key steps in the DFSS (Design for Six Sigma) process: 1) identify, 2)
design, 3) optimize, and 4) validate.
Design for six sigma uses tools such as CTQ (critical to quality) analysis, GD&T
(geometrical design tolerance), FEA (finite element analysis) and process design simulation
to ‘poke-yoke’ the planned design and promote a robust manufacturing process. In addition,
previous studies by Yu, J.-C. & Ishii, K. (1998), Taguchi, G. (1993), Chen, W., Wiecek, M.
M., & Zhang, J. (1999), and Eggert, R. J. (1991) link the use of design for six sigma to
increased product robustness.
CTQ is a common terminology that identifies a critical feature or component of quality.
Once a component is defined as critical to quality, different process control activities must
be conducted to ensure that the component meets the defined specifications; otherwise, the
product may fail the customer.
GD&T is used to define the components’ and features’ required dimensions for perfect
assembly; on the other hand, it also defines the allowable variation between components in
terms of their linear dimensions or datum references.
FEA is an engineering approach used to develop robust engineering products and process
configurations to design to fail-free or fail-safe specifications. According to Afazov, S.M.
(2012), FEA can be used to identify stressed and weakened areas and improve them
accordingly based on the manufacturing process or customer use. The FEA methodology
and its applications to new product development have been discussed by Pietrzyk, M., et al.
(2008) and Jahansson, H. (2004).
The aim of the process design phase is to configure the manufacturing process to suit the
new product design intent; as proposed by Zhenyuan, J., et al. (2011), process design can be
time - and cost - effective when the organization uses special tools and techniques to
develop the manufacturing process, such as the following: layout simulation, experimental
design, expert systems, and the intelligent manufacturing approach, among others.
Results: LDFSS tools applied into APQP Process for NPD
Based on the theoretical background presented in the earlier section, we can focus on key
elements of lean design for six sigma tools that can be introduced into the advanced product
quality planning process for new product development (see Fig. 7).
Figure No. 7. Lean Design for Six Sigma Key Tool (by Cruz, J.) .
I.Marketing & Business Case
V.Product and Process Validation
•Run at Rate
IV.Process Design
•PFMEA
•DOE & SPC
•Prodcess Simulation
III.Product Design
•DFMEA
•FEA •DOE & SPC •GD & T
II. Planning
•Project management
•Quality Function Deployment
Page 14
The full APQP process includes five stages or gates for the NPD process, with each step
contributing to the main goal of increasing cost effectiveness and optimizing the length of
the time-to-market cycle. Each step in the process includes specific tools, such as project
management, quality function deployment, finite element analysis, design of experiments,
and failure mode and effect analysis. The aim of this APQP case study is to present
evidence of the introduction of key tools from lean design for six sigma into NPD and
indicate the influence of these tools on product quality and reliability.
The following figure (see Fig. 8) contains a waterway for a commercial faucet or service
sink that is composed of three main elements: a brass waterway, a water spout and an o-
ring. To further analyze the potential failure modes while making the product design gate a
useful tool, failure mode and effect analysis can be used (see table. 1). The FMEA process
can be used in the design gate to identify the RPN (risk priority number). In this example,
the failure mode that triggers an RPN 240 occurs when the system begins leaking and may
experience liability issues. This, in turn, occurs when the o-ring loses compression due to
its proximity to a chamfer area.
Figure No. 8. Conceptual Design of a Waterway (by Cruz, J.).
Table No. 1. Design Failure Mode and Effect Analysis.
Description Function
Potential Failure Mode
Potential Failure Effects
SE
V
Potential Causes
OC
C Current
Controls
DE
T
RP
N
O-Ring groove center line too close to lead in chamfer
Waterway
Inproper o-ring compression cause leakage issue
Leakage 8 Inproper o-ring compression
10
To analyse machine process capability and evaluate poke yoke by design.
3 240
Industrial design will identify the overall dimensions of the components and the CTQ
(critical-to-quality) features that may cause issues and that are related to high RPN (see
Figs. 9 and 10). The CTQ characteristic for this waterway is the x-x´ dimension of the o-
ring’s center line and the starting point of the chamfer. This would be the location of the
water leak.
Page 15
Figure No. 9. Critical Dimensions Related to Industrial Design (by Cruz, J.).
Figure No. 10. Spout Tube and O´ring Leak Free Feature (by Cruz, J.).
Industrial design based on GD&T (geometrical design and tolerance) and DFMEA can be
used to determine the tolerance for each design reference (see Eq. 1). The following
calculation produces the upper and lower limits for the key dimensions.
Equation No. 1. Design Specification for Key Variables A, B and C.
.119.0
.131.0
value)(nominal 0.006.-
125.0
=
=
+=
LSL
USL
A
.744.0
.756.0
value)(nominal 0.006.-
750.0
=
=
+=
LSL
USL
B
.605.0
.645.0
value)(nominal 0.020.-
625.0
=
=
+=
LSL
USL
C
DOE and SPC are state-of-the-art techniques for simulating product performance through
manufacturing (see fig. 11). A process capability study shows evidence of the occurrence of
failure when the system begins to leak. Statistical analysis yields sufficient evidence to
confirm that the key dimension “c” is at a minimum according to the probability plot
analysis, and 3D software can be used to recalculate the minimum “c” (see Fig. 12). To
calculate the delta, it is necessary to take the “c” mean sample value and the standard
deviation (see Eq. 2) to calculate the natural upper limit and subtract from it the nominal
“b” critical delta. The delta can also be shown in a normal histogram plot (see Fig. 13).
CTQ 4
1.A
43.B
85.C
Page 16
Figure No. 11. Machine Process Capability Analysis (by Cruz, J.).
0,1280,1260,1240,122
Mediana
Media
0,12540,12510,12480,12450,1242
0,7540,7520,7500,748
Mediana
Media
0,7510,7500,749
0,680,660,640,620,60
Mediana
Media
0,6350,6300,6250,6200,615
0,80,60,40,2
99
90
50
10
1
Data
Cu
m P
erce
nta
ge
A
B
C
Variable
Intervalos de confianza de 95%
Statistical Summary A nalysis for Key Variable A .
Intervalos de confianza de 95%
Statistical Summary A nalysis for Key Variable B.
Intervalos de confianza de 95%
Statistical Summary A nalysis for Key Variable C.
Normal - 95% de IC
Probability P lot A nalysis for Key Var iables: A , B and C.
Figure No. 12. Waterway Leak Free Compromised - Failure Mode Occurrence (by Cruz, J.).
Equation No. 2. Delta Calculation to Failure Based on Upper Natural Limit.
( )
.059.0.691.0750.0
.691.0022.03625.0
=−=∆
=+=UNL
CTQ
Page 17
Figure No. 13. CTQ Condition Based on Random Sampling Analysis (by Cruz, J.).
0,760,720,680,640,60
18
16
14
12
10
8
6
4
2
0
Data
Frec.
B
C
Variable
Histogram for Key Variables: B and C.
Once the machine process capability is known, it can be input into a stack-up tolerance
analysis to calculate the process drift in addition to a safety factor (see Fig. 14 and Eq. 3).
The process drift is 1.63. sigma in addition to a safety factor of 15% to create a larger space
from the upper natural limit of “c” to the lower natural limit of “b”.
This approach focuses on the downsizing strategy of RPN while reducing the opportunity
of failure occurrence; following this approach, RPN decreases from 240 to 48 (see table 2).
The new “c” dimension can be calculated accordingly (see Eq. 4) and theoretical new cross
section of “c”. An illustrative histogram plot of the new redesigned “c” versus old “c” is
shown on Fig. 16.
Figure No. 14. Tolerance Analysis for Key Dimension C (Based on CTQ condition) (by Cruz, J.).
0,1300,1280,1260,1240,1220,120
LEI LES
Dentro de
General
0,7560,7540,7520,7500,7480,7460,744
LEI LES
Dentro de
General
0,680,660,640,620,600,58
LEI LES
Dentro de
General
0,680,660,640,620,600,580,56
No paramétrico
Normal
0,680,640,600,56
0,690,660,630,600,57
99
90
50
10
1
Porcentaje
Process Capability A nalysis for Key Var iable A . Process Capability A nalysis Key Var iable B.
Process Capability A nalysis for Key Var iable C. T olerance Interval A nalysis for Key Var iable C.Intervalo de tolerancia de 95%
Al menos 95% de la población cubierto
Gráfica de probabilidad normal
Page 18
Equation No. 3. Process Drift Calculation for Revised C Including Safety Factor of 15%.
.87.115.1*63.1
.63.1022.0
681.0645.0
%15 σσ
σ
==
=
−=
sfPD
PD
Table No. 2. DFMEA Revaluation (Effect on RPN).
Actions Recommended Resp. Actions Taken
SE
V
OC
C
DE
T
RP
N
To incorporate a safety factor on feature to eliminate the risk of failure mode
Design Eng. Safety factor implemented
8 2 3 48
Figure No. 15. Conceptual Design for Revised Key Variable Dimension of C (by Cruz, J.).
Equation No. 4. Tolerance Design Review for C Based on CTQ Including Safety Factor.
.563.0
.603.0
02.0583.0
.583.0)022.0(87.1625.0
87.1625.0
*
*
*
*
*
=
=
−+=
=−=
−=
LSLC
USLC
C
C
C σ
CTQ
Page 19
Figure No. 16. Theoretical Analysis for Revised Key Variable Dimensions of C (by Cruz, J.).
Discussion
This study presented the theoretical background on the NPD process and related functions
in today’s organizations as it relates to competition. NPD was identified as one of the top
priorities of every firm, which is why the NPD process must be optimized and oriented
toward customers to ensure the quality and reliability of products while minimizing
manufacturing costs. To fully deploy all NPD tools requires basic steps such as the
following: marketing and planning, design, process, product process validation and the
integration of operations from a concurrent engineering standpoint.
Lean design tools can easily be introduced into the advanced product quality planning
process to ensure the implementation of cost-effective new product development processes
intended to ensure product and process reliability and minimize failure during the design
stage. This approach will significantly impact goals regarding product quality and
reliability and customer expectations.
The effect on timing and cost is greatly appreciated by top management, and it is well
known throughout the firm when a strong, reliable product is launched that it is flawless.
All departments involved in the introduction of new products are aligned with the top
priorities: 1) safe launch, 2) reliable product quality, 3) timing, and 4) budget. Although
these four priorities appear to be opposing, they that must be met concurrently to ensure a
successful NPD launch.
The case study presents a typical, straightforward design. Even when the design and
development stages are complete, there is are opportunities for improvement when the new
0,760,720,680,640,60
18
16
14
12
10
8
6
4
2
0
Dat a
Fr ec.
B
C
Va ria b le
0 ,750,720 ,69 0,660 , 630,600 ,570,54
30
25
20
15
10
5
0
Dat a
F rec.
B
N ew
C
Va ria b leHi stogram
for
Key
Variabl es:
B
and
C.
Hi stogram
f o r
Key
Vari ables
B
and
C *.
Page 20
product enters the manufacturing process, as it is possible to address the potential for
failure due to leaks. This case study shows the application of the traditional stage-gate
process, which employs a very basic concept of a safe NPD launch, but not the application
of the advanced product quality planning framework, which aims for a flawless and cost-
effective NPD launch.
The NPD tool kit integrates DFMEA, CTQ, FEA, DOE, and simulation, among others,
which are used in the advanced product quality planning framework. In the case study, the
RPN decreased from 240 to 48. Although the potential for failure remains, the occurrence
of failure was reduced to a parts per million measure in the single digits, which indicated
that excellence in manufacturing and reliable product quality had been achieved in addition
to low-cost manufacturing. The tools work, and the knowledge is there; top management
must simply support the use of this approach to ensure successful NPD launches. Using this
approach will earn firms high recognition among end consumers due to their product
quality and readiness for manufacturing.
About the authors
Dr. Jesus Cruz has a BSc. in Industrial Engineering, a Master’s degree in Quality
Engineering, a Master’s degree in Operations Management, and a PhD in Operations
Management from UANL – Mexico. He is a member of CONACYT SNI – Mexico
National System of Scientists No. 32747. He is an executive member of ASQ – Monterrey
Chapter and a senior member of ASQ USA No. 63389331. In addition, he is an evaluator
for the Nuevo Leon State Quality Award and a research professor in the Business College
at UANL-Mexico. He has more than 14 years of experience in the automotive industry,
having filled a range of managerial positions in operations. Email:
[email protected] .
MSc. Berenice Mendez is a Bsc Industrial engineering, Master´s degree in Science.
Currently enrolled in PhD Program at UANL, Mx. She has been working as a finance
executive and teacher at undergraduate programs in engineering.
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