DMAIC Cycle for the New Product Launch Process: FMEA and DOE Applications for Built-In Oven

Abstract

Objective: Six Sigma-SS and the DMAIC-Define, Measure, Analyze, Improve, Control cycle are employed to enhance the success of the launch of a new built-in oven with a digital panel. Method: Following the define and measure phases, to identify and eliminate potential failures, Failure Mode and Effect Analysis-FMEA is conducted and control plans were composed during the analyse phase. In the improvement phase, the Risk Priority Numbers-RPNs obtained through FMEA and recommendations were listed. Using Design of Experiments-DOE, the lifespan of bulbs in ovens was maintained at the target value while reducing procurement costs. In the control phase, the results of validation experiments and the gains were reported. Findings: After reporting the RPNs related to high-risk failure modes and providing improvement recommendations, DOE and Analysis of Variance were employed to determine which type of oven and brand of bulb could be used. If implemented, the expected annual savings are approximately 20,000 Euros. Originality: This article focuses on an integrated approach for a product that is set for a new launch. It aims to improve design and production processes using the SS while also targeting cost reduction in procurement processes. To the best of our knowledge, no similar study has been encountered in the literature.