Design for six-sigma: process, service & product design

When implementing DFSS it is important to make the distinction between what you are actually designing. Is it a process, a service or a product, click the the table image:

While new process design may involve only a few of the organization’s functions or departments, the design of a new product or a new service has stakeholders throughout the company’s value creation process. Additionally, if errors or omissions in product design data are not addressed early, more costly changes are required later in the product development process, click the figure image:

The difference between product and service development is the level of detail and complexity mainly in the Optimize phase of the DFSS project. In product design projects, the Optimize phase is the phase when the design “becomes real.” First prototypes will be built; data must be collected on tangibles even if simulating the processes.

Advanced DFSS programs include a number of tools for the Optimize phase mainly for product design. Typical Six Sigma tools such as design of experiments may be advanced by robust design principles or mixture design concepts. It is however, critical to choose the right tool at the right time. This becomes especially important if Six Sigma is run in conjunction with Lean as sometimes stakeholders can become confused: the table below provides some clarification:

DMAIC First? Six Sigma Works Here
Some organizations consider going for Design for Six Sigma right away and not starting with process improvement (DMAIC). This seems attractive: DMAIC always means searching for problems that can be solved – and a lot of organizations (responsible persons?) do not want to admit to having problems.

Nevertheless, there are a number of good reasons for starting with DMAIC even in a creative or engineering environment: Budget-effective financial savings can be reported within a limited time frame, a number of projects can be executed simultaneously and internal success stories can be created, proving that Six Sigma works here – see the table below: