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Yazaki DFSS Activities

DMADV Navigator

An interactive reference for Design for Six Sigma practitioners working on new product development. Explore all five DMADV phases (Define · Measure · Analyze · Design · Verify) across five real automotive product programs — AR Head-Up Display, Wiring Harness, EV Charging Inlet, Automotive Connector, and Smart E-Fuse Box. Each phase surfaces the key questions to ask, the DFSS tools to deploy, the deliverables to produce, and a worked case outcome with concrete metrics. Built to support DFSS Black Belt programs and serve as a quick on-the-job reference for engineering teams designing automotive systems right the first time. DMADV Navigator

Kano Classification — Five-Project Drag-and-Drop

Five interactive Kano classification activities, one per project team (AR-HUD, Wiring Harness, EV Charging Inlet, Automotive Connector, Smart E-Fuse). Each team drags five product features into the correct Kano category — Must-be, Performance, Delighter, Indifferent, or Reverse — and receives immediate feedback explaining the placement. Used in the Day 2 Kano session of the DFSS Black Belt program. Open Kano activities →

FMA P-Diagram — Five-Project Drag-and-Drop

Five interactive Parameter Diagram classification activities, one per project team (AR-HUD, Wiring Harness, EV Charging Inlet, Automotive Connector, Smart E-Fuse). Each team drags twelve design factors into the correct zone — Control Factor, one of five Noise Factor categories (Piece-to-piece, Ageing, Customer usage, Environment, System interactions), or Error State — and receives immediate feedback explaining the placement. Used in the Day 3 Failure Mode Avoidance session of the DFSS Black Belt program. Open FMA activities →

Poka Yoke Idea Generator – Narrative Driven Mistake Proofing

A guided two-input tool that turns a real plant or design problem into 25+ targeted Poka Yoke ideas. The user writes a short System Thinking Narrative describing how the failure propagates through the system — customer impact, the layers where it went undetected, the source failure, and the root cause — then states the Trade-off the current system is preserving in a single “If we do X, then good effect, but bad effect” sentence. From these two structured inputs the tool generates 25+ Poka Yoke concepts spanning detection, prevention, and shut-down logic, classified by mechanism (contact, proximity, signal, fixed-value, motion-step) and by where they intervene in the process. Used in the Day 4 Mistake-Proofing session of the DFSS Black Belt program. Open Poka Yoke generator →

Structure and Function Trees →

TRIZ Innovation Agent

Move beyond brainstorming. Resolve contradictions with structure.

  • TRIZ Matrix to guide from Engineering Parameters to TRIZ Principles – TRIZ Matrix Tool
  • The TRIZ Innovation Agent is an AI-powered thinking partner that helps you frame technical and process conflicts using a disciplined “If–Then–But” structure, then apply TRIZ principles to generate focused, principle-driven solution directions. TRIZ Agent