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Six Sigma Green Belt Certification Workshop

LECTURE 8: Quality Function Deployment (QFD)

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ASQ Body of Knowledge I.C.1, I.C.2, I.C.3

I. Overview: Six Sigma and the Organization
C. Design for Six Sigma (DFSS) in the organization
1. Quality Function Deployment (QFD)
2. Design/process failure mode and effects analysis (D/PFMEA)
3. Road maps for DFSS

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Design for Six Sigma (DFSS)

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DMAIC approach of six sigma is focused on problem solving of existing

processes.
It does not focus on the designing of new product or processes.
As a six sigma practitioner one needs to understand the basics of DFSS
approach too.
Whereas tools used in DFSS are almost common as that of DMAIC.
Design for Six Sigma (DFSS) is a methodology:
To invent and innovate products, services and processes.
DFFS can be used to design entirely new products.

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Design for Six Sigma (DFSS)

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As the name suggests, DFSS guides:

Designers to create processes that can produce six sigma quality.
As well as services that meets six sigma capability.
DFSS can benefit an organisation by:
Completely understanding customers and stake holders requirements.
Launch projects on time and on budget.
Achieving greater market share.
Minimise problems during project launching.
Capable of generate high yields.

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Tools for DFSS

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The tools used by DMAIC and DFSS approach are almost common:
Quality Function Deployment (QFD)
Design/Process FMEA
Hypothesis testing
Analysis of Variance (ANOVA)
Box plots
Correlation and regression
Design of Experiments (DOE)
All the above tools are discussed in later chapters, based on the
requirement in a particular phase of DMAIC.
We will have brief introduction of QFD and FMEA in subsequent slides.

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Quality Function Deployment (QFD)

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A major tool of DFSS, and a process of planning for:

New products/services or
Redesign existing products/services.
Voice of Customer (VOC) becomes the inputs for QFD process.
QFD addresses customer related issues by formal questions like:
What are the product qualities which our customer desires?
What functions must be incorporated in that product/service.
How best can we provide our customer requirements.
Main tool for QFD is the basic requirement matrix of;
Customer requirements v/s design requirement matrix,
Named as House of Quality.
QFD will be covered in detail in later lectures.

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Failure Mode and Effects Analysis (FMEA)

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It is a prevention tool for the team for:

Identifying and anticipating potential failures.
Identifying potential causes for the failures.
Prioritizing these failures.
Recommending corrective action to reduce/eliminate failures.
There are two primary types of FMEA:
PFMEA or Process FMEA that focuses on Processes.
DFMEA or Design FMEA that focuses on product or component parts
FMEA will be covered in later lectures in detail.

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DMADV and DMADOV

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Two commonly used methodologies for DFSS are:

DMADV (Define, Measure, Analyse, Design, Verify).
DMADOV (Define, Measure, Analyse, Design, Optimize, Verify)
Basic difference is on O meant for Optimize.
Seems to simple difference, but many design process do not require to
optimize.
They are intended to produce minimally workable product/process.
Additional tools used in DMADOV are:
Design of Experiments (DOE).
Response Surface Methodology (RSM)
Evolutionary Operations (EVOP). Etc.
These tools help to refine the design parameters.

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Structured Designing (DMADV)

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Define

Measure

Analyse

Design & Verify

Initiate the project

Develop design
alternatives

Optimise detail level

design parameters

Scope the project

Discover and
prioritise customer
needs

Plan and manage

the project

Develop and
prioritise CTQs

Develop high level

design

Evaluate detail level

design

Evaluate high level

design

Plan detail design

verification tests

Measure baseline
performance

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Verify detail and

design of product

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Pilot testing

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Implement and
transfer to process
owners

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DFSS and DMAIC

DFSS

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For new product process design.

Establish six sigma capability product/process at
design stage itself.

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DFSS and DMAIC are not isolated.

Concepts and tools complements to each other.
Can be used at any stage.

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DMAIC

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Bring six sigma capability to existing product / process

Identifying projects and reducing the variation in
product / processes

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End of Section 2

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End of the section I. Overview: Six Sigma and the Organization.

The following subsections of ASQ BOK were covered in this section:
A. Six sigma and organizational goals.
B. Lean principles in the organization.
C. Design for Six Sigma (DFSS) in the organization.

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The final exams based on ASQ model carries 15 questions from this
section.
Attend model quiz related to this section.

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Next Lecture Process management for projects1 (BOK II.A)

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