Design for Six Sigma is designing to meet customer needs and process capability. That sounds rather complex, but in reality it is similar to the Six Sigma processes for continuous improvement, but starting with a clean slate rather than one that has defects. Design for Six Sigma is often broken down into the acronym of DMADV.
DMADV stands for Define, Measure, Analyze, Design, and Verify. During the Define stage, the project goals and customer needs are clearly defined. This is the reason the project exists in the first place. During the Measure phase, evaluate customer expectations to ensure that the products live up the company’s reputation as well. The next phase is to Analyze, where current processes will be evaluated to see how they fit with the proposed project. The most active phase is probably the Design phase, where the actual process will be laid out in detail, and finally that process is Verified to ensure that it performs as expected.
Using the founding thought of “work smarter, not harder”, each phase of the DMADV cycle is completed and evaluated. If at any point a flaw is found or a defect detected, the cause needs to be figured out and fixed before moving on. It is more advantageous and less expensive to fix problems as they are discovered rather than waiting to fix the problems all at the end. Additionally, the problems may make the project impossible to complete if they are not addressed as they arise.
Placing the Design for Six Sigma into your product development tool kit gives your company one more tool to use when developing new products and services to better meet the needs of your customers. This method helps turn customer needs and expectations into critical requirements for the product/service, which are now built into the project and not thought of at the last minute. Also automatically built into the cycle is the minimization of costs over the project’s lifecycle, which includes materials, man-hours, and waste along with the design to make the process and its products as close to mistake proof as possible as the process is built, which avoids some costly defects before the plan is even put into motion.
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