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Article
Publication date: 7 June 2022

Shreeranga Bhat, Jiju Antony, Gijo E.V., Rajesh Koul, Elizabeth A. Cudney and Ayon Chakraborty

While Six Sigma (SS) has been deployed effectively in Indian manufacturing and service sectors as a process improvement methodology, the implementation of Design for Six…

Abstract

Purpose

While Six Sigma (SS) has been deployed effectively in Indian manufacturing and service sectors as a process improvement methodology, the implementation of Design for Six Sigma (DFSS) for robust product and service development has not shown noticeable results. Therefore, this article aims to determine the critical failure factors (CFFs) of DFSS in the Indian context.

Design/methodology/approach

The paper presents the results of a pilot survey on the CFFs of DFSS in Indian companies. The survey participants were specialists in DFSS who have been involved in DFSS projects in their past and present companies. Moreover, the pilot study participants were DFSS Champions, Master Black Belts, Black Belts and Green Belts from the manufacturing and service sectors.

Findings

Company-wide applications of DFSS are very limited in India. Most of the DFSS project failures are reported in the Analyse phase of the project. The results indicated that all 18 CFFs used in the survey have a significant impact on project failures. Also, it was determined that all CFFs are positively correlated with each other. Further, a strong correlation was observed between the voice of the customer (VOC) and project selection and prioritisation. In addition, effective training showed a strong correlation with the right selection of tools.

Research limitations/implications

The pilot survey was based on a limited sample size. Moreover, the study is confined to only the Indian context and data were collected through the authors' networks. However, respondents were proficient, certified and involved in DFSS project deployment in the manufacturing and service sectors. Therefore, the study's findings are useful and meaningful to draw robust inferences.

Originality/value

To the best of the authors' knowledge, this is the first empirical study conducted in the Indian context to identify the reasons for DFSS project failures. The study's findings can aid academicians and practitioners in comprehending and critically examining the CFFs of DFSS before executing a project. Moreover, the research outcome motivates policymakers to create an ecosystem to effectively adopt DFSS for start-ups and micro, small and medium enterprises (MSME) to ensure a circular economy and support the “Atmanirbhar Bharat” initiative.

Details

The TQM Journal, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1754-2731

Keywords

Article
Publication date: 11 February 2021

E.V. Gijo, Shreeranga Bhat, Jiju Antony and Sung H. Park

This article aims to provide Design for Six Sigma (DFSS) practitioners, researchers and academicians with Ten Commandments to successfully deploy projects.

Abstract

Purpose

This article aims to provide Design for Six Sigma (DFSS) practitioners, researchers and academicians with Ten Commandments to successfully deploy projects.

Design/methodology/approach

The commandments are the brainchild of four authors' experience and expertise for more than 15 years of DFSS deployment in the spectrum of fields as a consultant, researcher, academic and Master Black Belt in Six Sigma and general quality management and engineering disciplines. Thus ascertained commandments were validated and classified through the “Delphi Study” to ensure its applicability.

Findings

The Ten Commandments from authors' perspective include: alignment of DFSS with organisational strategy; top management support and involvement; listening to the voice of the customers (VOC); effective training programme for right project teams; project selection and prioritisation; linking DFSS with ISO international standards; linking DFSS with organisational learning and innovation; linking DFSS with the 4th Industrial Revolution; effective use of DFSS methodology and the integrated tools within the methodology and reward and recognition schemes.

Research limitations/implications

The commandments presented in this article are the authors' personal experience in different industrial scenarios and settings and demographical locations. The authors are planning to conduct a longitudinal survey to understand further insights of these commandments with the input of several DFSS Black Belts and Master Black Belts, academicians and leading researchers from various countries.

Originality/value

All the organisation's stakeholders can use this article as general guidelines to ensure effective deployment of the DFSS approach.

Details

The TQM Journal, vol. 33 no. 8
Type: Research Article
ISSN: 1754-2731

Keywords

Article
Publication date: 23 March 2012

Ida Gremyr and Jean‐Baptiste Fouquet

Six Sigma and lean production are established concepts in industry and academia. Both have given rise to associated concepts that have been applied in product development…

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Abstract

Purpose

Six Sigma and lean production are established concepts in industry and academia. Both have given rise to associated concepts that have been applied in product development: Design for Six Sigma (DFSS) and Lean Product Development (LPD), respectively. Proposals are being published for the merger of DFSS and LPD, and the purpose of this paper is to discuss potential benefits and risks of such proposals.

Design/methodology/approach

The paper is based on an interview study encompassing 11 interviews at seven companies.

Findings

The results show that a possible merger of DFSS and LPD could prove beneficial in providing guidance both on the structure and the content of improvement efforts. Further, a merger has a potential of supporting radical, as well as incremental, improvements. However, differences in industrial practices that should be considered in applications of a merged initiative are the overall goal of the improvement work (cost reduction versus waste reduction), the emphasis on what to do or on how to do it, and the documentation demanded (extensive versus short and visual).

Research limitations/implications

This study has taken DFSS and LPD applications as its starting point, as the merged initiative of DFSS and LPD has started to develop further studies based on the implementation of the merged initiative would be of value. These studies could especially focus on the organisation of improvement work, identified in this paper as a potential area of conflict.

Originality/value

This paper discusses potential benefits as well as risks of merging DFSS and LPD based on industrial experiences. Consideration of the differences addressed, by practitioners as well as academics, will contribute to a well thought‐out design of a merger of the two concepts.

Details

International Journal of Lean Six Sigma, vol. 3 no. 1
Type: Research Article
ISSN: 2040-4166

Keywords

Article
Publication date: 24 January 2020

Marta Gomes Francisco, Osiris Canciglieri Junior and Ângelo Márcio Oliveira Sant’Anna

This paper aims to present a systematic review of design for six sigma (DFSS) methods applicable to the product development process (PDP) of durables goods and identify a…

Abstract

Purpose

This paper aims to present a systematic review of design for six sigma (DFSS) methods applicable to the product development process (PDP) of durables goods and identify a research opportunity on the subject proposing integration of DFSS and a reference model for the PDP. In this way, through the analysis of the theoretical references identified in the scientific databases, it was possible to propose a conceptual model for the PDP oriented to the DFSS.

Design/methodology/approach

This paper is based on the theoretical framework presented in peer-reviewed scientific research papers during the period 2000 to 2018 on the theme DFSS applied in the PDP, as well as such as the product development tools/techniques and statistics addressed. By means of key words defined by the acronyms of DFSS methods (DMADOV, ICOV, DMEDI, IDOV, DDOV, PIDOV, DMADIC, DCCDI, DMADV, IDDOV, CDOV and DCOV), DFSS and the acronym DFSS. Applying Boolean expression during the conduction of the searches through the scientific evidence at the Brazilian scientific database platform (Capes database). This database platform is maintained by coordination for the improvement of higher education personnel, which including Emerald Insight (Emerald), Scopus (Elsevier), Science Direct, SpringerLink, Taylor Francis, Scielo (Web of Science), Wiley Online Library, Web of Science (Clarivate Analytics), etc. It was obtained, by means of the searches, 269 papers related to subject DFSS, of which 18 papers had been critically selected for the composition of a conceptual model for the process of development of product guided to the DFSS.

Findings

This study presents a review of the literature (systematic review and content analysis) on DFSS and its effectiveness for the PDP. The DFSS methodology is disseminated in the scientific literature through a variety of methods that are often mistaken for the six sigma methodology – DMAIC, which is directed toward process improvement. The PDP integrated with the DFSS concepts contributes to eliminating possible failures during the design of a new product, directing to reduce costs and improve the quality of the product and process.

Practical implications

This paper presents a literature review that guided to a proposal of a preliminary conceptual model DFSS focused on the process of product development with the purpose of being a friendly model that meets the dynamics of the organizations and the expectations of the consumers.

Originality/value

Through the systematic review and content analysis, it was possible to observe that the DFSS methods applied to product development are not related to the PDP reference models available in the literature. In this way, the fusion of the concepts of the DFSS methods and PDP reference models for the construction and proposition of a preliminary conceptual model DFSS oriented to the process of product development intends to contribute in the development of new products with the reduction of time, reduction of the cost, competitive price and consumer satisfaction.

Article
Publication date: 26 March 2010

Gregory H. Watson and Camille F. DeYong

The purpose of this paper is to describe the historical approach to concurrent engineering (CE) which has resulted in product line management (PLM) and then evaluates the…

2217

Abstract

Purpose

The purpose of this paper is to describe the historical approach to concurrent engineering (CE) which has resulted in product line management (PLM) and then evaluates the theoretical models that have been proposed for design for Six Sigma (DFSS) in order to determine which model is able to provide the most consistent approach with historical development of PLM.

Design/methodology/approach

The approach begins with an overview of the approach taken by the Union of Japanese Scientists and Engineers (JUSE) in the development of a coherent quality methodology for structured analysis and problem solving – the Deming Wheel of plan‐do‐check‐act (PDCA) which has become the standard model in Japanese total quality management to define a logical decomposition in process management. In Japan, PDCA is the single logical model which has been broadly accepted as the construct for understanding how to develop both strategic and operational quality methods. The second step in the approach is to examine a similar American development of the model for statistical problem solving that is applied in the Six Sigma method for statistical problem solving: define‐measure‐analyze‐improve‐control (DMAIC). Next, the paper examines the historical sequence in the way the product development process has developed over the past forty years, with emphasis on its military origins (especially CE) and which resulted in the generic model for PLM. The final part of this paper examines the models that have been proposed to implement DFSS over the past ten years and evaluate their logical congruence with the engineering community's design process.

Findings

Problems in alignment with the engineering design process were identified with all of the DFSS models and with the non‐structured or “heuristic” approach to developing a coherent body of knowledge related to DFSS.

Originality/value

This paper provides a challenge to the quality community as well as to the academic community. The paper points out the need for rigorous examination of logical models that are proposed for guiding the thinking of practitioners in the use of quality methods for both the engineering of products and business systems. An expose of lack of rationality in the way an approach to DFSS has been investigated calls for more responsibility in the management of the development of this body of knowledge.

Details

International Journal of Lean Six Sigma, vol. 1 no. 1
Type: Research Article
ISSN: 2040-4166

Keywords

Article
Publication date: 18 December 2007

Jean‐Baptiste Fouquet

Many practitioners strive to increase the efficiency of their product development. In addition, smaller companies must satisfy customers’ expectations of their product…

Abstract

Many practitioners strive to increase the efficiency of their product development. In addition, smaller companies must satisfy customers’ expectations of their product development. These expectations can be e.g. use of specific methodologies such as Lean Product Development (LPD) and/or Design for Six Sigma (DFSS). This study attempts to identify differences and similarities between these methodologies and the connection between them. This comparison is of interest to practitioners that must choose a strategy for their product development as well as to researchers. The aim of both methodologies is to reduce waste and time of development and to raise the quality of a product at the very roots of the product: its development. LPD and DFSS help development managers to structure projects and focus as much as possible on customer expectations and satisfaction.

Details

Asian Journal on Quality, vol. 8 no. 3
Type: Research Article
ISSN: 1598-2688

Keywords

Article
Publication date: 18 December 2007

Sok Kwon, Kang Koon Lee and Young H. Park

Many 6‐sigma innovation companies are obtaining ISO9000 series or ISO/TS16949 certifications. However, not many of them have considered the integrated management of ISO…

Abstract

Many 6‐sigma innovation companies are obtaining ISO9000 series or ISO/TS16949 certifications. However, not many of them have considered the integrated management of ISO/ TS16949 at the time of 6‐sigma introduction. ISO/TS16949 focuses on the process of an overall company. In particular, APQP (Advanced Product Quality Planning) requires that from the beginning all the planning should have a clear quality planning business process. Each company can decide the best course of action to suit its individual needs. Lean DFSS in 6‐sigma offers the concrete development steps of the product development process. And if analyses of Input, Output, Target, Process, KSF, KPI, and FMEA is done in each process and clearly defined in APQP, mutual organic and effective systems can be initially achieved.

Details

Asian Journal on Quality, vol. 8 no. 3
Type: Research Article
ISSN: 1598-2688

Keywords

Article
Publication date: 6 March 2017

Mahmoud Awad and Yassir A. Shanshal

The purpose of this paper is to propose a new framework for early design stage utilizing the benefits of Kaizen events, and Design for Six Sigma (DFSS) methodology. To…

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Abstract

Purpose

The purpose of this paper is to propose a new framework for early design stage utilizing the benefits of Kaizen events, and Design for Six Sigma (DFSS) methodology. To gain a better understanding of the proposed method, a case study of a diesel engine development was presented where the proposed methodology was followed.

Design/methodology/approach

This paper proposes a hybrid Kaizen DFSS methodology consisting of four Kaizen milestone events with pre-work preceding these events. The events are in line with the four phases of DFSS methodology (define, characterize, optimize, and verify).

Findings

In order for the proposed method to succeed, few key enablers should be available such as management buy-in and support, effective resources utilization, and proper planning. However, this methodology should be utilized for key projects where criticality is high and deadlines are nearby.

Practical implications

As proved by two projects, one of them is presented in this paper; the use of the proposed methodology is effective and can bring significant positive changes to an organization.

Originality/value

Although Kaizen is an old and well-known process, it is to the best of the author’s knowledge that Kaizen has not been utilized in the early design stages of new product development projects. In this paper, a hybrid methodology combining traditional DFSS systematic approach conducted using Kaizen improvement events is proposed and supported by a real-life case study.

Details

International Journal of Quality & Reliability Management, vol. 34 no. 3
Type: Research Article
ISSN: 0265-671X

Keywords

Article
Publication date: 18 December 2005

Kang Koon Lee, Sangbok Ree and Young H. Park

Six Sigma uses DMAIC (Define, Measure, Analyze, Improve, Control) methodology as the process of a solving problem. Enterprises already propelling Six Sigma successfully…

Abstract

Six Sigma uses DMAIC (Define, Measure, Analyze, Improve, Control) methodology as the process of a solving problem. Enterprises already propelling Six Sigma successfully, such as Motorola, GE and consulting companies, also traditionally propose DMAIC methodology. But, from activating Six Sigma, enterprises and Six Sigma‐consulting companies propose Six Sigma methodology matching indirection part of office and R&D part. As an exmaple, DFSS (Design For Six Sigma) is part of R&D application in GE. This study investigates Six Sigma methodology corresponding to the Right Process of the kernel factor. Especially for the optimum design of R&D, the study revises the definition of DFSS and the general organization through Lean DFSS methodology research and analysis.

Details

Asian Journal on Quality, vol. 6 no. 3
Type: Research Article
ISSN: 1598-2688

Keywords

Article
Publication date: 10 June 2014

Ida Gremyr and Mattias Elg

The purpose of this paper is to examine the value of a developmental learning view on implementation of quality management (QM) concepts. QM concepts are common in various…

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Abstract

Purpose

The purpose of this paper is to examine the value of a developmental learning view on implementation of quality management (QM) concepts. QM concepts are common in various organizations; some implement them smoothly, others struggle and sometimes even abandon the initiatives. What is then a successful implementation – is it the use a specific QM method as a standard problem solving approach, or is it that learning has occurred during implementation?

Design/methodology/approach

The paper is based on an illustrative case study carried out at a hospital in western Sweden. The data have been collected through about 130 hours of participation in project work by the first author and through seven face-to-face interviews of about one hour each.

Findings

It is shown that a Design for Six Sigma pilot project with a narrow view on implementation could be regarded as a failure, but it gave rise to much learning and new improved ways of working. Hence, it is argued that a developmental view on implementation can support learning by an emergent and experimental approach to implementation processes.

Originality/value

Much research has been done on how to increase the success rate of implementations of QM initiatives, e.g. procedures to follow to reach an outcome where the new way of working is standard procedure. Less research has problematized the implementation process, questioning what a successful outcome of an implementation is.

Details

International Journal of Quality and Service Sciences, vol. 6 no. 2/3
Type: Research Article
ISSN: 1756-669X

Keywords

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