Often, the unwanted behavior is detected as a failure or a countable event that is a by-product of the physics behind the failure. But once you are counting failures and then trying to rapidly apply logic and reason to fixing the problem, you are at a distinct disadvantage. You are off in the weeds at this point and cannot efficiently conduct Root Cause Analysis (RCA). Stop counting failures and instead, measure functions. This provides apples-to-apples congruity between the physical variables (Xs) driving the unwanted performance and treats them as leading indicators of impending failure. The "root" in RCA is the physics-based Y=f(Xs) relationships and the impact that noise parameters have on these foundational relationships. "Impending failure" is another term for measured functions (Ys) that can undergo trend analysis as the Xs are intentionally varied under the guidance of reason and logic. In turn, the reason and logic should be guided by engineering science, knowledge of physical law, and a healthy dose of luck-enhancing designed experimentation (DOE). This is the fastest way to learn about root cause relationships inside the functional physics of your designs. Reason and logic alone are not enough; what you measure and how you methodically comb through candidate independent and interactive contributions from your controllable Xs and unwanted noise parameters are the "speeding factors" that underwrite the integrity of your sense of urgency.

Topic 2: I have been trained in DFSS and Critical Parameter tools, but...

Formal training in DFSS (Design for Six Sigma) and Critical Parameter tools provides a foundation, but it erodes fairly quickly when it is not followed by practical application. This doesn't mean you shouldn't invest in training! A balanced approach is to use formal training to build the knowledge and awareness of a tool, method, or best practice, then immediately follow through using any or all of these strategies:

1. Review the training materials and examples just before you actually apply them on your project.
2. Contact your internal Subject Matter Expert (SME) to guide you through your application.
3. Train just-in-time when possible; this is called synchronous training and is provided by PDSS in the form of hands-on workshops specifically designed for your project applications.
4. If you have undergone PDSS training, watch the PDSS CPD&M videos to refresh your memory by hearing and seeing the material in the context of when you first learned it. There are 52 video segments covering a comprehensive set of methods across the continuum of CPD&M body-of-knowledge.
5. PDSS can provide a SME if you don't have such resources in your company or enterprise; we'll come and roll up our sleeves with you in your labs to get the job done quickly and with focus - results are immediate.
6. Innovate with tool applications as you repeat their applications. I see wonderful twists and turns applied to many of the tools to great effect. If in doubt, call us (585-330-9293) for a sanity check before you use a tool in a unique way.

If you are really under time pressure, don't just bypass essential tools. PDSS has a wealth of experience and we can help you safely "cut corners" when you absolutely must. A good project plan and schedule will prevent having to cut corners very often, but even the best laid plans get co-opted. That's okay- but be sure to get all the help you can when you have to take a shortcut. We all have to do this from time-to-time and it's a great opportunity to innovate. Just don't make this form of development a habit! Chapter 7 of my book Six Sigma for Technical Processes is all about Fast Track Commercialization. It contains a logical approach to going fast when you have to. In our next newsletter I will discuss the logic behind cutting corners in development projects. In the meantime, stay cool, and remember: as much as possible - do things right the first time!