已知的 DFSS 方法

Known Design for Six Sigma (DFSS)

Methodologies

Design for Six Sigma (DFSS) is a product development approach that complements the Six Sigma
problem-solving methodology. Promoted as “Six Sigma goes upstream,” Design for Six Sigma
involves changing or redesigning the fundamental structure of the underline process or product.
The major objective of Design for Six Sigma is to “design it right the first time” to avoid
painful downstream experiences. The term “Six Sigma” in the context of Design for Six Sigma can
be defined as the level at which design vulnerabilities are not effective or minimal. Generally, two
major design vulnerabilities may affect the quality of the design entity (Yang et al. 2003):

 Conceptual vulnerabilities that are established because of the violation of design axioms
and principles.
 Operational vulnerabilities due to the lack of robustness in the use environment.

Different Design for Six Sigma Roadmaps

 

Unlike the Six Sigma’s trademark methodology of DMAIC, there is not a universal roadmap for
DFSS (Chowdhury 2002). The acronyms range from DMADV (define, measure, analyze, design,
verify) to IDDOV (identify, define, develop, optimize, verify) to DCOV (define, characterize,
optimize, and verify) and many more. See next heading for available 11 Design for Six Sigma
methodologies. If you want to learn more about difference between DFSS & DMAIC, refer to
this article.

Despite these naming differences, all versions of

Design for Six Sigma share fundamental
strategies and tools that promote a common
goal: “to create a data-driven product
development culture that efficiently
produces winning products”(Soderborg
2004). Thus, the Design for Six Sigma
methodology is still a straightforward, four or
five-step process, just like Six Sigma’s DMAIC.

 According to Yang et al. (2003) Design for Six Sigma is

needed when:
 

1. A business chooses to replace, rather than repair, one or more core processes.
2. A leadership or Six Sigma team discovers that simply improving an exciting process will
never deliver the level of quality customers are demanding.
3. The business identifies an opportunity to offer an entirely new product or services.
The 11 known Design for Six Sigma (DFSS) Methodologies detailed below is known for their various
abilities to eliminating difficulties resulting from variability in engineering, manufacturing, and
transactional processes.

Common Design for Six Sigma  methodologies

 

Below are the different acronyms of the 11 known Design for Six Sigma (DFSS) Methodologies
Identify and described below. These methodologies.

1. DMADV: Define, Measure, Analyze, Design, Verify

 2. IDDOV: Identify, Define, Develop, Optimize, And Verify.
3. DCOV: Define, Characterize, Optimize, Verify
4. IDOV: Identify, Design, Optimize, Validate
5. DCCDI: Define, Customer, Concept, Design, Implementation
6. DMEDI: Define, Measure, Explore, Develop, Implement
7. DMADOV: Define, Measure, Analyze, Design, Optimize, Verify
8. ICOV: Identify Requirement, Characterize, Optimize, Verify
9. CDOV: Concept Development, Design Development, Optimization, Verify Certification
10. IIDOV: Invent, Innovate, Develop, Optimize, Verify
11. IDEAS: Identity, Design, Evaluate, Assure, Scale-Up

1.DMADV (Define, Measure, Analyze, Design,

Verify).
 DMADV is a Six Sigma Methodology that concentrates primarily on developing new services,
product or process as opposed to refining it. The DMADV approach is predominantly used when
executing new initiatives and strategies for the reason that its basis on data, early success
identification, and detailed analysis. The DMADV methodology should be applied to:

 Non-existent process or product requiring development. And…

 Existing process or product still in need of meeting Six Sigma level or client specification.
DMADV Phases includes:

 Define: Defining project goals including customer focus while using market forecast and
competitor analysis to create project charter and plan.
 Measure: The measured phase involves determine, measure, and ranking customer needs
using the CTQ matrix, interviews, and surveys.
 Analyze: The analyze phase include selecting the best, most innovative concept using an
affinity diagram, brainstorm, etc.
 Design: Develop a design to meet customer needs with the help of Design Tools
 Verify: This phase validates with a pilot run and transition to operations team to close the
DFSS team.

DMADV Process
This article describes the concept of the DMADV Process in a practical way. After
reading you will understand the definition and basics of this powerful quality
management tool.

What is the DMADV Process?

DMADV is a Six Sigma quality method that is used to design new processes, with the
goal of delivering the final product to the client correctly. The goal of the DMADV
Process is the creation of a high-quality product, whole keeping the customer and the
customer’s need in mind during every phase of the project. Each letter of the
acronym DMADV is one of the five main phases of the project improvement initiative:
Define, Measure, Analyse, Design en Verify.
Six Sigma
Six Sigma is about process improvement as part of quality management. Existing
products and/or services are improved using analytical techniques and statistics. Six
Sigma focuses on reducing variability in matters that are perceived as Critical to
Quality (CTQ) by the customer. These CTQs are very important and vital to quality; it
is about the internal critical quality parameters that relate to the customer’s wishes
and needs. As such, CTQs are quality characteristics of the process or service that
meet the requirements of the customer.

DMADV Process
DMADV is about the development of a new service, product or process. The DMADV
Process is particularly useful for the implementing of new strategies and initiatives.
Each phase is explained below.

Define

In this first phase of the DMADV Process, it is about identifying the goal of the
project, the process or the service. Not just from the perspective of the organisation,
but also from the perspective of other stakeholders, including customers. It should be
clearly defined which guidelines are important for the development of a product or
service, and if there are any potential risks and what the production schedule is.

During this first phase, the project manager determines what the most important
customer needs are regarding the product or service to be newly developed. He
determines this by using relevant, previously gathered customer information and
customer feedback.

In the definition phase, a garden furniture manufacturer can decide to focus on the
production of wooden sun loungers. Based on previously collected customer
information, the manufacturer knows it is very important to customers that the wood
being used comes from fair trade.

In addition, customers have indicated that the lounger should be adjustable in three
positions, have a high back support and head support and have an environmentally
friendly coating that allows the lounger to be left outside. During this definition phase,
the manufacturer can also determine if it would be lucrative to design such a sun
lounger.

Measure
This phase of the DMADV Process is aimed at the collecting and recording of data that
are relevant to the CTQ measures that have been identified during the first phase.
The data that is collected during the measuring phase are essential to the process, as
it will be used to drive the rest of the process.

In the case of DMADV, there are no CTQs in the measuring phase yet. After all, there
is no new product yet, let alone a production process. During this measuring phase, it
is about determining what the customer thinks is important about a new product.
These factors are subsequently linked to quality, which leads to CTQs. If a value is
assigned to all design components, this leads to an effective approach to start the
production process. It is important to determine which components of the production
process are critical to all stakeholders. The customer requirements will eventually be
translated to clear project objectives, in order to get a product that can distinguish
itself from the competition.

The garden furniture manufacturer now links what the customers think is important to
the CTQs. If it is not possible to source fair trade wood, production cannot start. The
same goes for the environmentally-friendly coating and the design that needs to meet
the minimum requirements; 3 positions, high back support and head support. During
this measuring phase, the manufacturer checks whether the design costs,
manufacturing costs and raw materials costs are worth the eventual selling prise.

Analysis

The analysis phase of teh DMADV Process is closely linked to the measuring phase,
because the project team will analyse and test all the gathered data. This results in a
good basis to measure improvements during the production process. During this
analysis phase, design alternatives are developed and they determine the optimum
combination of requirements. An estimate of the total life cycle costs of the design is
also made during this stage. After exploring the different design alternatives, a rough
product design is created (functional specification) that meets the previously defined
CTQ’s as much as possible.

In this phase, the garden furniture manufacturer will check out different importers
from who they can purchase fair trade wood. They will determine the origin of the
wood, so they can use it as background information for sales. They also analyse
different environmentally-friendly coatings, their advantages and disadvantages and
the strengths of the different options. The analysis of different designs will receive
close attention as well. Analysing is a time-consuming phase and the manufacturer
would be wise to set a deadline to prevent cost-overruns.

Design

The design phase of the DMADV Process consists of the design of the product or
service that fully matches the customer requirements. During this phase, the project
team uses data from the previous phases, leading to a product that is suitable for the
customer with all possible additional adjustments that might be needed. It is a
detailed and high-quality design which will be made into a prototype. During
production of this prototype, they also look at the production process. The goal is not
just to develop a production process that creates good products, but one which is also
logistically efficient.

Based on the earlier analysis, the garden furniture manufacturer has made certain
choices. They have found a supplier for fair-trade wood, know which environmentally-
friendly coating they will use and they have chosen a design in which adjusting the
lounger is quickest, safest and easiest and in which the back support and neck
support are connected in a good way. In the manufacturing process, close attention
will have to be paid to the layout of the woodworking machinery and what route the
process will follow (routing), so no time is wasted and an x number of loungers will
leave the factory every hour.

Verify

The verification phase of the DMADV Process might be the final phase, but it is not
the end of the process. To safeguard quality, it is important to continue to verify and
make adjustment to the product where necessary. In this last phase, the design is
final and the product is ready to be sold. During this phase, the project team receives
feedback from the customers and user experiences, and they will make necessary
adjustments to better meet the customers’ needs. The project team will also
determine additional CTQ measures to be able to monitor customer feedback after
delivery of the final product.

During this phase, the garden furniture manufacturer feels it is very important to find
out what its customers/users think of the wooden sun lounger. Are they satisfied
about the fair-trade wood that was used, do they have sufficient information about
the origin of the wood, do they find the lounger comfortable and is it user-friendly? Is
the head support pleasant and in line with the back support and is the coating
sufficiently water resistant? If after six months it turns out that there are some
complaints about annoying spots in the wood damaged by weather, then the coating
might need to be changed. In that case, the garden furniture manufacturer will use
the data collected earlier during the analysis phase to find a proper alternative.

DMADV applications
DMADV is mainly used for products or services that do not exist yet and still have to
be developed by a company. In addition, it is also used for existing products or
services that not yet meet certain customer specifications. For each DMADV Process
improvement project, additional emphasis can be put on certain components, even
though the goal remains the same; addressing a problem that has been identified and
achieve the desired results.
A DMADV Process improvement project can take several months or even years, but
the final result is a product or service that fully meets the customers’ needs and
wishes.

DMAIC versus DMADV

The DMADV Process is very similar to the DMAIC model, which stands for Define –
Measure – Analyze – Improve – Control.

Both methods are used in Six Sigma methodologies and in many respects they
match. Both are designed to make business processes more efficient and effective.
However, the models are not interchangeable and are used for different business
processes.

However, there are some important differences. The first three letters in the acronym
match. The biggest difference is the way in which the last two steps of both models
take shape; DMAIC is about improving and controlling a business process. It defines a
business process and its applicability, while the DMADV Process defines the
customer’s needs, as it relates to the service or product.

The DMAIC model measures current processes of a process, while the DMADV Process
measures customer needs. In addition, DMAIC checks in the meantime to improve a
business process and to reduce or even eliminate defects. At DMADV, it is about
developing an appropriate business model that meets customer requirements.

2.IDDOV: (Identity, Define, Develop, Optimize,

And Verify).
 

IDDOV offers the essential framework for product development and highlights the use of step-by-
step phases to accomplish Six Sigma. IDDOV phases include:
  Identify: This phase involves identifying client needs, prioritize them, and translate them
into design product.
 Define: In this phase, the product specifications are clearly defined as the consumer needs
and wants are transformed into products.
 Develop: In this phase, a feasible concept is developed to meet the specified requirements.
 Optimize the Design: This is the phase where design optimization is maximized at the
output to create the idea.
 

3.DCOV: (Define, Characterize, Optimize,

Verify).
 

The DCOV methodology has a defined stage which is first explored. The DCOV phases include:

 Define stage: This stage identifies the Critical to Satisfaction (CTS) drivers, and establish an
operating window. This stage is further separated into three areas: Inputs, Action, and Output.
 Characterize stage: This stage is usually completed using a two-step approach, system
design, and functional mapping. The goal in both steps is to characterize the design
robustness.
 Optimize stage: The optimize stage generally takes a two-step approach, robust
performance, and product design. The goal for both is to improve robustness.
 Verify stage: The verify stage also takes a two-step approach, overall DFSS assessment,
and test and verify. The goal for both is to confirm that the capability and product integrity
over time.
 

4.IDOV (Identify, Design, Optimize, Validate).

 

IDOV is amongst the popular six sigma methodology and standards for designing products and
services. IDOV involves a four-phase process parallel to that of traditional Six Sigma improvement
methodology. The IDOV phases include:

 Identify Phase: This phase begins with a formal design involving development team
gathering competitive analysis, VOC, performing and developing CTQs.
 Design Phase: The Design phase highlights CTQs and includes classifying functional
requirements, developing substitute concepts, evaluating alternatives and select the best-fit.
It also deploys CTQs and predicts sigma competence.
 Optimize Phase: The Optimize phase necessitates the use of process capability data and
statistical method to tolerancing, developing large design elements, forecasting performance,
and optimizing the design.
 Validate Phase: This phase entails the testing and validating of the design.
 
5.DCCDI (Define, Customer, Concept, Design,
Implementation)
 

The DCCDI methodology has many comparisons and connections with the DMADV process like
Define, Measuring, And the Design stages. Thus, the Implementation stage is the only addition to
this methodology that is linked to the formation and commercialization of a good or service.

6.DMEDI (Define, Measure, Explore, Develop,

Implementation)
 

The DMEDI methodology takes a creative approach to making new robust process, products, and
services. The DMEDI methodology place emphasis on gaining substantial competitive benefits or
quantum leaps over current environs. The DMEDI phases include:

 Define Phase: The Define phase offer complete charters with clear business issues,
anticipated results, and scope limits.
 Measure Phase: The measure phase necessitates more examination due to little, if any,
existing Critical Customer Requirements (CCR), Process Definition, or Baseline Outputs (Ys).
 Explore Phase: The explore phase is dedicated to producing a workable design for a new
process.
 Develop Phase: The Develop Phase delivers an optimal design based mostly on meeting
customer desires.
 Implement Phase: In the Implement phase, a pilot is conducted. The pilot is a permanent,
full-scale deployment that delivers full charts and control plans to monitor the activities
involved in the new process.
 

7.DMADOV (Define, Measure, Analyze, Design,

Optimize, Verify)
 

The DMADOV methodology is another favorite Design for Six Sigma (DFSS) Methodologies.
DMADOV uses a refinement action on its design. DMADOV forces more consideration to optimize
the design by using additional tools to refine design parameters. These tools include Evolutionary
Operations (EVOP), Design of Experiments, and Response Surface Methodology (RSM).

 
8.ICOV (Identify Requirement, Characterize,
Optimize, Verify)
 

The ICOV methodology is also renowned, especially in the manufacturing industry. The ICOV
approach develops and expands business performance. The method also works on important
design projects while applying various strategies and tools to the designing and redesigning
services. The methodology also seeks to increase market speed, improve reliability and quality,
innovate grow, and better client satisfaction.

9.CDOV (Concept, Design, Optimization, Verify)

 

CDOV is another popular methodology used in products and services design that meet six sigma
standards. CDOV consist of a four-phase process similar to the five phases of traditional Six Sigma
improvement methodology.

 Concept Phase: This phase takes inputs from the Voice of the Customer (VOC) to produce
the best product concept and requirements.
 Design Phase: This phase detects vital data using administrative wisdom, engineering
philosophies, DFSS methods, and tools. Useful needs are recognized, substitute concepts
assessed, and competence evaluated.
 Optimize Phase: This phase gives optimized nominal and tolerance settings for significant
input constraints. They are defined by routine analysis of the functional output required to
performed.
 Verify Phase: This phase consists of testing and validating the design to ensure it is
consistent.

10.IIDOV (Invent, Innovate, Develop, Optimize,

Verify)
 

The IIDOV methodology uses a general technology development process which can be specified
regarding controllable gates and phases. These general gates and phases are useful elements in
aiding communication on how to handle product development with discipline, order, and
structure.  The IIDOV methodology structure uses research and technology development divided
into four discrete phases:

 Invent and Innovate Phase: Involves creating a workable technology concept.

 Develop Phase: involves developing the technological idea to yield better results.
 Optimize Phase: Gives the robustness of the baseline technology used
 Verify Phase: This phase consists in testing the platform and other sublevel technologies in
line with the efficiency process.
 

11.IDEAS (Identity, Design, Evaluate, Assure,

Scale-Up)
 

The IDEA methodology uses deliverables, enabling tools, requirements, and tasks to add
discipline, measurable, and structural results to guarantee strategic growth and activation of the
product. The use of technological selections is united to provide capable growth support and meet
the business goals. The IDEAS make use of five phase for product and technical project defined by
the following:

 Identify Phase: The identify phase includes markets, segments, and the prospects available
to the project.
 Define Phase: This phase details the project requirements and other product architectural
substitutes.
 Evaluate Phase: The evaluate phase includes product alternatives compared to other
competitive products.
 Activate Phase: This phase ranks every resource and individual product projects to
commercialized. Testing and efficiency ability would also be checked.
 Scale-Up Phase: This phase entails the addition of necessary modifications needed to suit
the market demands.

CONCLUSION
 

The 11 known Design for Six Sigma (DFSS) Methodologies aids businesses and organizations
create new processes, products, and services in a manner that guarantees customer satisfaction.
The various methodologies listed and explained above find usefulness in multiple fields, and your
choice of methodology is dependent on the field and product.

I would also like to emphasize deploying Design for Six Sigma (DFSS) is very challenging in
Small & Medium Sizes Enterprises. So, plan carefully before you embark on this journey!