Reliability deployment in distributed manufacturing chains via closed-loop Six Sigma methodology

This paper proposes a Six Sigma based framework to deploy high product reliability commitment in distributed subcontractor manufacturing processes. The study aims to expand the Six Sigma tools in applications, where products are designed and developed under the fast time-to-market requirement. The reliability deployment is driven by two incentives: the customer satisfaction and the reduction of the warranty cost. A closed-loop control mechanism is created between the upper and the lower manufacturing streams to identify and remove the early life failures occurred during the initial system installation. A cross-functional team is formed to implement Six Sigma tools for resolving critical failures arising in the upper manufacturing stream. The ultimate goal is to achieve high product reliability in the shortest time when the product time-to-market is essential for gaining the market share. Finally, the proposed control mechanism is demonstrated on the system designs drawn from the semiconductor testing industry.