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Description

Designing to the Optimum Sigma can enable companies to profit from a lot of money that current operations waste. Optimum Sigma is NOT 6 is the first book that guides engineers and managers through the process of setting design specifications to meet assembly requirements and minimize overall cost. The methodology shows how to decrease defects without significant increases in product costs, thereby increasing profitability and production capacity. The defect-costs relationship was described in very generic terms in earlier statistical process control books. Those books focused on manufacturing process improvements while assuming that design specifications would be appropriate and correct. The book shows why legacy approaches have failed and the cause and effect relationships between factory rework, part variability, design specifications, and overall production costs. Instructions are provided in how to produce a design that will optimize costs and factory flow, assure customer satisfaction, improve profitability, enhance workforce morale, and be environmentally efficient through proper specifications. Downloadable files for customer application are available through the book's website.
According to the most recent published data from the National Association of Manufacturers and Industry Week, manufactured goods contributed 2.18 trillion dollars to the economy of the United States in 2016. Applying Industry Week's average defect rate of 2.7%, that figure includes at least $58 billion wasted to defective goods. Given that it typically costs ten times as much to fix a defective assembly as it does to produce a defect free unit, the real scrap and rework numbers grow to between fifteen and forty percent of most manufacturers operating costs. The methodology described in Optimum Sigma is NOT 6 targets eliminating at least eighty percent of that rework, the rate generally attributable to engineering errors.