This program helps Six Sigma practitioners apply DFSS concepts so that they can foresee and eliminate potential defects before and during the design process
Design for Six Sigma (DFSS) is a powerful problem solving methodology aimed at tackling a core issue facing many of today’s products and services – that 80% of all defects are “designed in.” Design flaws can prevent standard Six Sigma methods such as DMAIC from achieving true “Six Sigma” levels of performance. Breakthrough improvement ultimately requires a Six Sigma team either create new products/services or to redesign existing ones using DFSS.

Course Description

BMGI’s DFSS for Product Design course helps Six Sigma practitioners further their understanding and application of Six Sigma concepts into designing new products. This five day program delivers a thorough education on the DMADV (Define-Measure-Analyze-Design-Verify) methodology and helps students to master a variety of techniques to help them design processes. All of the topics covered are universally applicable to the design of any type of product.

BMGI’s DFSS training is built around the idea that “Design” is a truly cross-functional undertaking vs. the sole responsibility of the “Product Designer.” While statistical design tools are an integral part of this course, the importance of the voice of the customer, financial analysis and supplier selection are also emphasized.

BMGI’s DFSS instructors have extensive experience in leading, training and coaching DFSS teams from a wide variety of industries worldwide. All of our instructors are certified Master Black Belts with an average of five years experience leading successful Six Sigma projects within major corporations.

This class is a fundamental component of BMGI’s comprehensive Master Black Belt (MBB) certification program and is highly recommended for every MBB candidate.


This program starts with capturing the voice of the customer, then moves into defining product, system and subsystem requirements. The course agenda is organized into four content areas: Launching and leading DFSS projects

  • Voice of the Customer
  • Introduction to DFSS and the DMAD methodology
  • Statistical Design Tools

Product Design for DFSS


Day One

  • Why Design Projects Fail
  • DFSS defined
  • DFSS vs. DMAIC
  • Integrating DFSS with existing Design Methodologies
  • The DMADV process
  • How Do You Know if You Need a New Product?
  • Tollgate Reviews
  • Project Risk Analysis & Design FMEA

Day Two

  • Design Project Financial Analysis
  • Capturing the Voice of the Customer (VOC)
  • Translating the VOC into Design Requirements
  • Quality Function Deployment (QFD)

Day Three

  • Design Scorecards
  • Requirements flowdown and Capability flowup
  • Robust Design
  • Product Tolerance Analysis

Day Four

  • Monte Carlo Simulation
  • Statistics of Reliability
  • Analysis of Reliability Data
  • Reliability Predictions

Day Five

  • Monte Carlo Simulation
  • Statistics of Reliability
  • Analysis of Reliability Data
  • Reliability Predictions