Common DFSS Methodologies

Design for six sigma is the suggested method to bring order to product design. 70-80% of all quality problems are design related.


Four stage of IDOV methodology

Identify:- Use a team charter, VOC, QFD, FMEA and Bench-marking

Design:- Emphasize CTQs, Identify functional requirements, Develop alternatives, evaluate and select

Optimize:- Use process capability study, Statistical tolerancing, Robust design and Six sigma tools

Validate:- Test and validate the design.


The DMADV method for the creation of a new product consists of following stages

Define:- Define the project goals and customer needs.

Measure:- Measure and determine customer needs and specification.

Analyse:- Analyse the process options to meet customer needs.

Design:- Develop the process details to meet customer needs.

Verify:- Verify and validate the design performance.


DMADOV method is used to develop new processes or products at high quality levels, or current process requires breakthrough (more than incremental) improvement

Define (Define the project):- Project goals, Identify the customer and customer requirements

Measure (Measure the opportunity):- Determine the customer needs and specification. Benchmark competitors and industry

Analyse (Analyse the process options):- What options will meets the customer needs? Determine creative solutions.

Design (Design the process):- Develop a details process, design experiments that verify the design meets customer needs.

Optimize (Optimize the process):-Test the new process to evaluate performance levels and impacts. Re-design the process (as necessary) to meet customer specifications

Verify (Verify the performance):- Verify the design performance and ability to meet customer needs. deploy the new process.

Design for X (DFX)

Design for X (DFX) is defined as a knowledge based approach for designing products to have many desirable characteristic as possible. characteristic includes- safety, quality, reliability, testability, manufacturability, assembly, environment, serviceability, maintenability, user friendliness appearance, packaging, features and time to market.

Robust design (Robust Engineering)

The use of robust approaches for design is a process that (when used) can produce extremely reliable designs both during manufacture and in use. robust design uses the concept of parameter control to place the design in a position where random noise does not cause failure.