Only about 60% of new products launched are actually a success and that for every seven new product ideas, only four make it to development—and then only one will succeed.
Throw in the manufacturing problems that will need to be corrected and it becomes easy to see that finding and fixing defects is not enough.
Most new product development processes do not operate at a Six Sigma level.
Organizations that have implemented Six Sigma quickly learn that if they do not Design for Six Sigma, they will not achieve it.
Design for Six Sigma (DFSS) is an approach to designing products and services, and their enabling processes, to ensure that they meet customer expectations.
As you evolve in Six Sigma, you realize more about the importance of having DFSS process. As you learn you apply the tools more and more frequently.
You can learn much more with the Quality Pro's Toolbox which contains a Design for Six Sigma PowerPoint Training Program.
Design For Six Sigma
Most defects are "engineered into" the system.
Product and process complexity has a direct effect on defects. The more complex the process or product, the larger the number of opportunities for defects.
Product simplification is the cornerstone. Rigorous methods are needed to drive down process steps, parts count, fastener count, special tooling, reorientation, forms, and so on.
The traditional approach to product and process design generally involves several functional departments working in series.
This approach lengthens the development process and increases the opportunities for defects at each step of the process.
Communication between groups is lacking due to the serial nature of the process engineering.
I'm sure you've seen it. Engineering changes are the accepted norm and as schedule pressures mount "firefighters" emerge as the heroes of the day.
Each challenge must be quickly resolved with short-term fixes – there's no time to eliminate root causes or they're viewed as too expensive to fix at this point and are therefore not pursued.
Design for Six Sigma (DFSS) on the other hand is a parallel (concurrent) activity where all applicable functions are represented within a cross-functional team.
All relevant knowledge, information, and data is made available to the team so that decisions are "data based" versus the traditional "judgmental" basis.
Product and process designs can therefore be developed together; meaning that the product and process can be made optimal relative to each other.
Like its parent Six Sigma, DFSS uses a disciplined set of tools to launch high quality products and processes.
It begins by conducting-
It rigorously addresses-
Once you identify the gaps and the voice of the customer-
DMAIC or DFSS Flowchart
Design for Six Sigma uses a set of tools and methods in the design of new products or services and their supporting processes.
Executing the process ensures that the outcome remains as simple and cost effective as possible while serving the needs of the customer.
The guiding principles ensure product/service definition decisions are "data based", and made within an Integrated Product Team environment.
Customer requirements are identified, prioritized, and translated into design requirements rather than just making broad-based assumptions. This allows proper cost and performance trade-off decisions to be made.
Specific component or process step targets are established as a basis for product/service or process definition.
Design for Six Sigma Application Tool Examples
The DFSS process and tools are used to design products, services, and manufacturing and transactional processes to meet customer requirements with minimum steps and parts to minimize opportunities for defect and improve sigma levels.
May 10, 16 09:24 PM
A Quality Control Plan is a documented description of the activities needed to control a process or product. The objective of a QCP is to minimize variation.
May 10, 16 08:49 PM
The Largest Collection of Free Six Sigma Tools and Training on the Web!
May 10, 16 07:28 PM
The Weibull distribution is applicable to make population predictions around a wide variety of patterns of variation.