Page 38 - Design for Six Sigma for Service (Six SIGMA Operational Methods)

20 Chapter One

1. IDOV (Identify, Design, Optimize and Verify): The IDOV project proce-
dure is usually used for new designs.
2. DMADV (Define, Measure, Analyze, Design, and Verify): The DMADV
procedure is usually used for redesign projects.
The DFSS strategy can also be applied to processes, because in many cases
the original design of the process is fundamentally flawed; merely patching
the holes in the process will not yield satisfactory performances. DFSS for
Process is a Six Sigma approach that will involve changing or redesigning
the fundamental structure of the underlying process. The goal of DFSS for
Process is to design or restructure the process in order to intrinsically
achieve maximum performance.

DFSS for Process is needed
• When a business chooses to replace, rather than repair, one or more
core processes.
• When a leadership or Six Sigma team discovers that simply improving
an existing process will never deliver the level of quality customers are
demanding.
• When the business identifies an opportunity to offer an entirely new
product or service.
Technical approaches for DFSS for Process are thoroughly discussed in
Chap. 10.

Lean Six Sigma
Lean Six Sigma (George 2003) is a combination of lean manufacturing
(Womack 2000, Liker 2004) and regular Six Sigma process improvement
strategy featured by DMAIC. Lean manufacturing practice is based on the
Toyota production system, which features the following principles.
1. There are many wastes (muda) in production processes. The wastes
are the activities that do not add value to the products. These are
• Overproduction
• Unnecessary inventory
• Unnecessary transportation
• Unnecessary movement
• Waiting
• Defective product
• Overprocessing
The muda should be eliminated from process steps. A value stream
map is an effective way to find muda and guide process improvement