Design for Six Sigma

Typical Situations

Wind turbine breaks during a peak load of thunderstorm Kyrill

You always suffer from late and hence costly product design changes in your development process?

You sometimes notice that a new product that you brought on the market does not meet your customers’ needs?

You want to move the current fire-fighting culture in your company towards a problem prevention culture?

Our Solution

Design for Six Sigma (DfSS) is a methodology to develop new products, processes or services in a structured way to design those right the first time. The strong emphasis on customer satisfaction and product quality ensures to launch well-received products on the market. DfSS reinforces the systems engineering / systems design approach and helps to truly understand and optimize product functional behavior by means of mathematical transfer functions. Rather than the traditionally applied determi-nistic analysis using safety factors, Design for Six Sigma uses a stochastic approach to make products robust against real-world conditions. With a specific roadmap that helps development teams to apply the appropriate tools at the right phase, Design for Six Sigma ensures that the right questions are asked and fact-based decisions are made at management reviews to:

Upfront quality planning with computer aided engineering (CAE) using DfSS

Our Method

Since day one, Innovensys has been at the forefront of thought leadership in Design for Six Sigma. Whilst our competitors in this area have been working with a bundle of independent and time-consuming tools, our product development experts deep dived into the Design for Six Sigma methodology to precisely define the interrelationships between various tools. Building on this fundamental understanding Innovensys has developed a unique DfSS training curriculum and approach that ensures efficient and effective application.

Innovensys educates and implements a structured set of logically linked tools and has integrated the pragmatic Failure Mode Avoidance approach into the Design for Six Sigma methodology:

  • VOC & Survey Design
  • Kano Model & Survey
  • Quality Function Deployment (QFD)
  • Project & Design Scorecard
  • Introduction to TRIZ & SIT
  • Morphological Analysis
  • Pugh’s Concept Selection
  • Axiomatic Design
  • Boundary Diagram
  • Function Definition
  • Part-to-Function Matrix
  • Function-Driven Design FMEA


  • Value Analysis (VA/VE)
  • Parameter Diagram
  • System Interface List
  • Design VMEA
  • Enhanced Robustness Checklist
  • Intelligent Verification Planning
  • Robustness Demonstration Matrix
  • Taguchi Robust Design
  • Classical Robust Design
  • Design of Experiments 
  • Statistical Tolerancing
  • Verification & Validation