IF you believe, as we do, that new Products/Processes should be launched on time, at/under budget and meet customer requirements, we share your belief & DFSS will help make it happen! 

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What is Design for Six Sigma (DFSS)

As companies successfully implemented 6σ, they discovered that to move past the 4.5σ wall, 6σ needed to be designed in. DFSS is used to to collect and verify the voice of the customer on new/revised products/processes and translates the requirements through the use of statistical, lean, and other tools to create a 6σ product/process. DFSS will shorten the development cycle time by over 30% and save $$$. Additionally, if DFSS is executed correctly, there will be little need for DMAIC projects in the future!

DFSS is an “ADD ON” to the Product Development process to be robust, faster, more cost effective, and meet Customer Needs. To be most effective, there needs to be a New Product Launch Phase Gate Process in Place. If your New Product Launch process needs improvement, please click below for the “New Product Development” page

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  • Unfortunately, there are too many examples of New Product Launches that do not use a Phase Gate approach or the associated DFSS tools.

    • Products that are not launched until 2x -4x after original timeline
    • Product launches that cost 2x – 10x original budgets
    • Product that starts production with scrap rates from 10% to almost 100%
    • Process launches that bring a department, organization, company to its knees
    • Product launched with no agreement/definition with the Customer on what a “Quality” product is
    • Product launched with visual defect terms such as, Zero Paint Defects, Zero blemishes, Zero wrinkles, Zero foreign matter, etc… without regard for qualifiers such as at 1x magnification under 100 lumens at 3 feet. Which leads to ongoing quality issues for the life of the product
    • Engineering “throwing the product over the wall” to let the Production folks figure it out later – without any regard to cost, delivery issues, and escapes to the customer
    • Literally a million widgits in the warehouse because of failure to understand what the Customer wanted
    • Eight new Products launched at significant development time, cost and disruption to the factory to only sell less than 5 each. 

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