What is Design for Six Sigma (DFSS)? Learn now!

In the 1980’s, the Six Sigma methodology became known worldwide when it was used in Motorola and General Electric (GE) processes.

In the moment that these companies started to adopt Six Sigma to increase their competitiveness in the market at the time, the following question arose:

Is it possible to use Lean Six Sigma for development or to remodel any product or service?

It was in this context that Design for Six Sigma emerged, a methodology that aims to accurately understand all phases of a project. Avoiding the need for rework for future fixes.

Want to learn about this technique? So let's go!

What is Design for Six Sigma?

Design for Six Sigma or simply DFSS is a methodology used to design a new product, from the initial phase to construction.

DFSS steps do not have a fully defined rule. The definition of the procedures that will be used depends exclusively on which type of company is adopting this methodology.

DFSS brings statistical tools that aim to reduce costs and improve the product. But the main objective of Design for Six Sigma is to add value to the product, through the client's well-being and technological innovations.

The expected accuracy level for processes using Design for Six Sigma is at least 4.5 sigma (less than 1 defect in a thousand samples). However, these numbers can be much better, reaching values ​​greater than 6 sigma.

To obtain such accurate levels it is essential that the customer's needs and expectations are fully known before any project begins. In other words, the voice of the customer is the priority of the process.

An important point about Design for Six Sigma that must be taken into account is that the excessive use of the tools of this method, without knowledge of the final objective and improvement opportunities, makes Design for Six Sigma an inefficient model.

When to use Design for Six Sigma?

Below I will list 3 examples of when Design for Six Sigma can be applied, meeting expectations.

1. The moment that the company intends to start a project or process from scratch

2. The moment that the process in question has reached its maximum performance level (process entitlement). In other words, when a certain process is operating at its maximum level and it is desired to increase this production, another more efficient process must replace the old one.

3. The moment that the improvement of the product or process through the DMAIC method, keeping the current technology, no longer meets the requirements established by the consumer. If this occurs, a redesign must be performed.

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Types of Design for Six Sigma Methodology

1. DMADV

The most popular method for implementing DFSS is the DMADV methodology. It aims to increase the turnover of new product launches by a given company in the market. In addition, it has a solid base of statistical and engineering data as tools.

DMADV consists of 5 phases. Are we going to learn more about them all?

Define: This step has the function of defining the objectives and the real needs of the customers. At this stage, the project schedule is also defined. It is very important to know how much time is available to perform the task, as well as how soon the product will be launched on the market

Measure: This step is responsible for measuring and determining consumer needs, in addition to obtaining data from competing companies that are a reference in the market. In other words, here the project requirements are translated into reliable numbers.

Analyze: Here, the analysis of all project execution options is performed. Its purpose is to define and prioritize new ideas and alternatives. It is at this stage that we will start creating the product, through prototypes and computer simulations

Design: Its purpose is to develop the project in a detailed way. Building prototypes very close to the final version. In this phase, small-scale productions are carried out in order to reduce production costs. The financial review and the supply plans are also carried out in this step.

Verify: The verify phase, as its name suggests, is responsible for verifying the project's performance and whether the client's needs are being met. All validation of the tests performed in the Design stage must be done here, and only then can large-scale production begin.

2. IDOV

The IDOV methodology (Identify, Design, Optimize and Validate) is among the most popular Design for Six Sigma methodologies. It is a process composed of 4 phases: Identify, Develop, Optimize and Validate.

Identify: This phase starts with the formal development of a project that aims to meet customer specifications

Design: Here customer specifications are transformed into requirements and functional alternatives. A process of reducing the list of solutions is carried out, in order to filter the best alternatives

Optimize: In the optimization process it is necessary to use a good data acquisition method, in addition to a good statistical analysis

Validate: The validation step consists of validating all the data obtained.

3. DCCDI

This methodology is very similar to DMADV, especially in the define, measure and design phases. DCCDI is an acronym for Define, Customer, Concept, Design and Implementation.

Below, I bring you the 5 steps for implementing this methodology:

Define: In this step, the goals and real needs of customers are defined

Customer: Here, all the analyzes made to serve the customer are finalized

Concept: Concept ideas are studied here. At this stage, the development and review of the selected ideas is carried out

Design: Just like DMADV, the design is made to meet all design specifications

Implementation: At this stage, the implementation is complete and the sale of the product or service can already be done.

4. DMEDI

The DMEDI methodology uses a creative approach to creating new processes, products and services. Prioritizes obtaining benefits that are competitive. The DMEDI phases are:

Defines: As in all previous methodologies, it is responsible for capturing the project's objectives

Measure: Here the measurements of all project parameters are taken

Explore: Dedicated to producing the viable design for a new process

Develop: The development phase offers an ideal project, in order to meet all customer requirements

Implement: In the implementation phase, the product begins to be produced on a large scale.

So, are you looking to learn more about Lean Six Sigma?

Lean Six Sigma is a methodology that seeks to increase the profitability of companies through the improvement of their processes.

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