What is Lean Six Sigma – DFSS

Design for Six Sigma is a process for the conception and design of either new processes for multiple execution, one-off processes or new products. It was conceived to ensure that processes and products were capable of achieving the levels of quality that improvement projects were trying to attain. Usually a DFSS initiative starts when the current processes are not capable of yielding what the company strategically demands in terms of performance. When a process, line, machine, organisation, cannot meet the specified requirements, then technical or functional redesigns are needed. DFSS starts by capturing the VOC -Voice of the Customer- by identifying the customer’s requirements and by building them into the process.


Customer requirements are translated into process requirements, and then into product or service specifications. Building a process from scratch by taking the customer into account is undoubtedly a big advantage; customer requirements are included in simulations and predictions, and quality is designed in. A paradigm shift takes place: from reactive quality to predictive design quality. Robust design and reliability enter the equation.


  • Generally speaking, it is considered that solving a defect in the design phase is 100 times less expensive than solving a defect in a live product.
  • DFSS projects also reduce project timelines by up to 30%.
  • In our experience: 20% reduction in the lead time to build a chemical plant; 60% reduction in construction defects.