Design for Six Sigma

Tackling quality from the start

Now more than ever quality is being the main focus on industrial activity from the conception of the product to the manufacturing and main logistic operations. As an answer to this desire a major method was born: Six Sigma. As its name indicates it concentrates on sigmas which are mathematical indicators of deviation or variability, for the sigma process the methodology followed is DMAIC which consist of five phases one for each letter (Define, Measure, Analyze, Improve and Control).

To design or redesign a product there is also another sigma technique known as Design for Six Sigma or DFSS. Unlike DMAIC for six Sigma, the phases or steps to follow are not completely defined and almost every company follows a different DFSS method depending of what suits their company, market and over-all culture the best.

A popular DFSS methodology is DMADV, which has the same number of letters and therefore the same number of phases and overall feeling as DMAIC. This process just as DMAIC was defined by the Motorola Company as part of their sigma efforts.

The efforts made in each step of DMADV can be summarized as:

· Define: in this first step objectives are defined, opportunities and client need are identified, and a team of work is picked. One of the main elements of this phase is the project charter in which we will organize the main information related to the product to be developed. It must include the establishment of the problem, the opportunities identified, and the importance of each, reach, calendar and general planning and the resources to be engaged.

· Measure: In this second phase products and processes to de designed are identified as well as client final requirement and critical to quality aspects (CTQs).

The main output of this step of work are prioritized CTQs, a voice of the costumer chart (VOC), and the Quality Function Deployment (QFD) or House of quality. Another important aspect of this stage of the process is benchmarking competitors and industry.

· Analyze: During this phase different design alternatives are to be developed, we should focus on design features and planning to cater to the customer requirements and expectations.

· Design: In this phase design is defined in detail and a verification plan of development is made. Design components are put to test, and also a prototype design is made. A an output of the stage we will end up with tested high level design, tested detailed design, plans for process control and completed design reviews.

· Verify: A pilot is executed and results are analyzed. Later solutions reached are applied to great scale products. Decide whether or not the Project is meeting the main objectives.

As an output you’ll have a working prototype with it’s documentation, a full plan for implementation, and the product will be ready to be transitioned from the design team to the process management team.

For this methodology for design it is important as always to keep the initial and client objectives and desires in mind through all the process always making sure necessities are being met with the design. DFSS is an important tool in preventing possible problems within a product to be manufactured and also a tailorable method that will allow it to be used on many different scenarios of design or redesign.