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Scroll down to see the DFSS tools
DFSS can be loosely defined as...
any systematic approach to design
or re-design any product or service
While the target ratio of defects might be 6 sigma (or higher),
the design team can choose any other target quality ratio,
(such as 1 defect per thousand opportunities, or 1 defect per 10,000 opportunities...)
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Designing a product (or service) and a production process to produce such a high level of quality requires the design team to thoroughly understand:
DFSS is the label used for just about any systematic attempt to understand those 3 things.
The most popular tools used for Design for Six Sigma are
DMAIC is the acronym for the popular approach within the Six Sigma community
to apply the scientific method
for process improvement
(usually with an emphasis on quality improvement)
DFSS can be understood as an attempt to apply the DMAIC methodology to product and process design.
Unlike the rigidly structured 5 steps of DMAIC,
there are many (widely varying) approaches to product and process design, which all claim the label of DFSS.
Perhaps the most popular is DMAVD
In practice, the team will often add one more phase
to Optimize the design, which then becomes DMADOV
Your Systems2win templates come with an entire suite of DFSS templates
that your design team will find very useful when implementing any of the many popular approaches to Design for Six Sigma.
To avoid confusing newcomers to lean six sigma,
the most complex DFSS tools have been split into an optional bundle of templates, but many of these tools are very simple to use,
and are therefore included among the Foundational Lean Toolkit (owned by every Systems2win user)
FMEA Failure Modes and Effects Analysis
This single FMEA template can be used for both:
DFMEA (during the Design phase)
PFMEA (to continuously improve the Process)
Use your FMEA template to anticipate problems, and to design processes and products to reduce risks
Download free trial FMEA template
To more carefully control the most severe or high-possibility risks
Learn more about the Control Plan template
Root Cause Analysis
also known as Cause and Effect Diagram, or Ishikawa Root Cause Analysis Fishbone Diagram
Your Systems2win templates give you the choice of several different types of Root Cause Analysis tools, to analyze different types of situations.
The fishbone template has a special feature that empowers you to click a button to import already-known causes from your FMEA so that your team has a helpful starting point to then brainstorm other potential risks and problems that should be included in your FMEA.
Download free trial Root Cause Analysis tools
Brainstorming & Affinity Group Tool
Six Sigma template to brainstorm ideas, then quickly organize them into affinity groups to stimulate even more ideas
Learn more about Brainstorming
also known as Thought Map Relations Diagram
To identify root causes of a complex, nonlinear problem.
(Use a Cause and Effect Fishbone Diagram to identify root causes of less complex, linear problems.)
Learn more about Relations Diagram
8D Problem Solving
also known as Corrective Action Report
To provide a systematic way for a team to resolve a problem that has uncertain root causes
in a way that systematically ensures that root causes have been identified and verified, and that permanent corrective actions are validated for effectiveness and instituted in a way that prevents the problem from ever recurring or escaping again.
It has been said that "an FMEA is an 8D waiting to happen". What if it does happen?
Corrective Action Request
also known as Supplier Corrective Action
The Supplier Corrective Action Report template does not pre-suppose that all of the rigid formality of the 8D process will be required. This simple Word template is structured as a one-page letter that simply requests the supplier to deal with a non-conformance issue.
Use your SIPOC template to identify and eliminate wastes of any kind: hazardous wastes and emissions, scrap, energy, packaging...
Download free trial SIPOC template
Process Flow Diagram
Before creating a PFMEA —
use the Process Flow Diagram to identify Sources of Variation, and desired Deliverables (ideal Functions) for each Process Step.
aka Parameter Diagram
Before creating an FMEA — use the p diagram to analyze Inputs and Outputs and Noise Factors and Control Factors that can affect performance of desired Ideal Functions, and minimize Error States.
Before creating a DFMEA —
use the Interface Matrix to identify and clarify interfaces between environment, systems, sub-systems, and components that are beneficial or detrimental to functionality.
Also provides P-Diagram input/outputs and noise factors
aka Item/Function worksheet
Before completing the Function and Requirements columns of the FMEA form, use this Function/Requirements worksheet to identify and clarify Functions and corresponding Requirements.
aka Product Characteristics Matrix
When creating a PFMEA — identify process steps that can compromise characteristics of the product or service that are noticeable and important to the customer.
aka DVP&R, DDVPs, DVPR
Formalized testing of product or service to ensure compliance with all requirements.
House of Quality
Quality Functional Deployment Matrix
One of the most sophisticated quality improvement tools to provide a guiding structure for a cross-functional product development team to rapidly design and deploy new products and services
Download free trial QFD template
Cause and Effect Matrix
A simpler quality improvement tool than the QFD, with a similar objective:
To identify the few process input variables that provide the greatest opportunity to improve the key process outputs
Customer Segmentation Worksheet
Quality improvement template to identify and focus attention upon the sub-segments of customers that generate the most value from each product or service
Voice of the Customer Data Collection Worksheet
To plan and manage the collection of Six Sigma customer data from existing company data, listening posts, surveys, interviews, point-of-use observation, and more
Learn more about Voice of the Customer templates
Voice of the Customer Requirements Translation and Kano Analysis
Quality control template to translate potentially vague customer comments into measurable functional requirements, thereby strengthening your team's ability to design and deliver products and services that truly delight your customers
Tool Selection Matrix
Use your Tool Selection Matrix (1ToolSelection.xlsx) to choose the right tool,
and to see which tools are split into the DFSS Tools bundle, and which tools come with the Foundational Tools
Download free trial Tool Selection Matrix
These same DFSS tools are used for Design for Six Sigma, Design for Manufacturability, Design for Lean Manufacturing, and DMADV.
Your DFSS tools also come with many other useful tools for Lean Six Sigma
to empower every team member
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