Design for Six Sigma (DFSS)
DFSS aims to develop or redesign the product to eliminate manufacturing/process errors and engineers’ systems to avoid problems at the outset. The replaces the try, test, modify approach and provides a first time right product that has no errors & also requires less aftermarket services. The main focus being streamlining the production and business processes to eliminate mistakes, improve morale and save money.
What We Do
It is believed that although achieving Six Sigma level of quality i.e. 3.4 defects per million opportunity, is feasible in theory but in practice many product’s quality could not be improved beyond 4.5 sigma (1350 DPMO). This is due to the fact that there are significant numbers of manufacturing process variations or the result of errors in the product and process design which could not be corrected on the shop floor.Achieving six sigma level of quality is feasible only when the product design / development process takes care of eliminating design errors at a very early stage of product development. In essence, the excellence in manufacturing alone cannot help achieve zero defects; excellence in design is also required to achieve this target.
The traditional product development process has limited capability to achieve first-time right new products. In order to challenge the traditional product development process, and to achieve zero defects in design, a science called ‘Design for Six Sigma’ was developed by automobile and aircraft manufacturing industries and has become a perfect science today with a well-structured product development process called IDOV (Identify-Design-Optimize-Verify). SSA implements the DFSS with help of the following tools:
How We Help Clients
- Implement DFSS methodology for developing new products with shortest lead-time, zero defects and lowest cost
- Use the IDOV Approach (Identify-Design-Optimize-Verify) approach for designing first time right products