Design for Six Sigma2019-12-16T17:08:13+01:00

How does it work?

Our DFSS Roadmap contains 3 major streams and the technical / methodical stream is linked to a costing stream if target costing is necessary. Depending on project specific requirements and situations we integrate also an interaction with Data Mining tools. So our DFSS-Roadmap consists of:

  • Technological Design
  • Design to costs
  • Data Mining

We decided to work with the DMADV approach. Of course there exist further models but this is secondary and the goals are the same, more or less intensive. A description of phases by a model is less important than a causal procedure. The basic way of a design project is divided into 30 steps shown by our Macro Roadmap. The starting and exit points can be selected depending on the specific project issues.

30 Steps of the DFSS – Roadmap

When starting a concrete design project it’s very important to define the present situation and the goals to be achieved. Based on such a clear defined task all of the DFSS tools, which should be applied during the project work, must be selected and a schedule should be set up.
In reality there might be quite different projects, some may contain a design of potential concepts and a selection of the best one as a project outcome, others contain a detailed product or process design.
The whole DFSS toolbox is shown at our detailed DFSS-Roadmap with all existing decision points.

DMADV phases content

In this phase a design project will be defined and documented:

What are the key requirements and expectations on this DFSS project, what should be designed and why?

  • Create a development strategy
  • Set targets and product idea
  • Develop the business case
  • Plan and define a project plan
  • Define resources and gates
  • Create an evaluation
  • Fix starting point and exit on the roadmap
  • Communication plan
  • Define target costs
In this phase all relevant requirements from all customers are collected segmented, compacted and prioritized. These informations are the base for a design of alternative concepts.
  • Collect and compile the customer’s requirements
  • Prioritize and translate the requirements into CTS`s (specific and measurable customer requirements), specify target values ​​and tolerances if possible
  • Transform CTS’s into functional requirements
  • Develop alternative design concepts
  • Introduction into the creative toolbox
  • Basics of TRIZ
The different design concepts generated are to be analyzed with respect to the criteria which would cause trouble later on during production if not satisfying.

  • Identify performance and functionality
  • Calculate the complexity
  • Estimate risks (based on data)
  • Determine costs
  • Identify and assess critical elements in design and construction
  • Analyze essential critical couplings
  • Develop a concept selection matrix and select the best concept
  • Pugh concept selection
  • Optimize and finalize the concept
  • Create specifications
After a selection of the best concept the detailed design will be initiated, for a product and / or for one or more processes (depending on the project issues).
  • Determination of all necessary product components
  • Design Score Cards 3+4
  • Process Modelling (DoE or Data Mining)
  • Evaluation of the relevant transfer functions (Y = f (x))
  • Optimal parameterization and tolerance setting
  • Ensure the robustness of the design
  • Test/measurement and sampling strategy
  • Demonstrate a robust product design
  • Determine the required process capabilities and comparison with the existing processes
  • Systematic generation of process design concepts
  • Analysis of the concepts related to
  • Functionality / performance
  • Complexity
  • Risks
  • Costs
  • Malfunctions
  • Elementary couplings
  • Optimization and finalization of the best concept
  • Axiomatic process design, detailed phase
  • Evaluation of optimal parameters
  • Development of the necessary control concept
  • Machine – and Process Qualification
This is the last phase and the finanlization of the design project. The whole project goals are compared with all of the achieved performance of the design and it is a final review before hand over to production

  • Evaluation/review the product – and process performance
  • Demonstrate and proof life cycle and reliability
  • Evaluation/review of the purchased part and supplier capabilities
  • Review of the development order
  • Finalize the project and production documentation
  • Delivery of the product and/or process design to production
  • R&D handover on the base of appropriate agreed KPIs
  • Hand over to series production

We offer the following Consulting services:

  • Workshops, a review of the existing situation and development of a design strategy for innovations, product and process design
  • Deployment of DFSS into the organisation
  • Integration and harmonisation of DFSS with the existing Product Development Process (PEP)
  • Coaching of DFSS projects from the starting point to SOP, adjusted to your specific needs
  • Support in Data Mining applications for design purposes

Let’s get started!

We’re looking forward to providing you with a quote, a demo or any information about our services.