DFSS Tools & GB Project

Organizations that believe in the Six Sigma paradigm, pursue the DFSS methodology religiously. Trainings are imparted, & the teams are GB certified. Is there an adequate understanding of the importance of DFSS, & the relevance of their tools. Here is a brief on what I learnt from that exercise

One of the most important learning's of the whole process is the importance of team work. All the activities revolve around Team work. 

Each of the tools revolve around this central theme to achieve a collective synergy.

When we used the SIPOC, we were able to figure out who are the concerned stakeholders? What did each of the stakeholder bring to the table. (inputs) and what were there expectations (outputs), what are the possible ways to transform these inputs to outputs (processes)

Since it is done in a team it ensures that all of the stakeholders inputs and their respective expectations are considered

When we used the TPM it ensured that all participants thoughts about the problem  are captured. There was a lot of tacit knowledge

At individual levels, Aspects that certain individuals were aware of, and some were not. Thus knowledge was shared (and captured) concerns  raised were addressed (through action items with assigned responsibilities & dates). Thus at the end of the exercise the collectively had enough information & were on the same page.

When we did an RCA as a Team, it ensured that we looked at the problem from different dimensions. It is true that as individuals we may not have adequate information on all dimensions (6M) of the problem. But collectively as a team we were able to get a broader perspective on the root causes

Again when the team did an FMEA, each of us had our own opinion on what could fail and what the impact would be. All of which were captured. Collectively we were able to decide on the probability / severity of each of these. We were able to come up with some good ideas on how to mitigate them effectively.

Other then the above ones we did use the QFD, C&E, Pareto, Pugh Matrix etc… As individuals each one of us has his own opinion on what is important, relevant, of priority etc. In a team sometimes few individuals and their ideas dominate. To Arrest such possibilities these tools helped us to Quantitatively figure out what was important, relevant, of priority and vital.      

Now does this ensure that we reach six sigma levels of quality? Definitely not.

However what it does ensure is that "you have taken into consideration all stakeholders requirements, considered various alternatives at each stage of the project, made the right choices or taken optimum decisions, not just as individuals, but collectively as a team. Thus minimizing the possibilities of making mistakes".