Design for Six Sigma and lean product development

Ida Gremyr · Jean‐Baptiste Fouquet

69 citations0/0 files storedInternational Journal of Lean Six Sigma

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Quality and Supply Management Management and Optimization Techniques Product Development and Customization

Abstract

Purpose Six Sigma and lean production are established concepts in industry and academia. Both have given rise to associated concepts that have been applied in product development: Design for Six Sigma (DFSS) and Lean Product Development (LPD), respectively. Proposals are being published for the merger of DFSS and LPD, and the purpose of this paper is to discuss potential benefits and risks of such proposals. Design/methodology/approach The paper is based on an interview study encompassing 11 interviews at seven companies. Findings The results show that a possible merger of DFSS and LPD could prove beneficial in providing guidance both on the structure and the content of improvement efforts. Further, a merger has a potential of supporting radical, as well as incremental, improvements. However, differences in industrial practices that should be considered in applications of a merged initiative are the overall goal of the improvement work (cost reduction versus waste reduction), the emphasis on what to do or on how to do it, and the documentation demanded (extensive versus short and visual). Research limitations/implications This study has taken DFSS and LPD applications as its starting point, as the merged initiative of DFSS and LPD has started to develop further studies based on the implementation of the merged initiative would be of value. These studies could especially focus on the organisation of improvement work, identified in this paper as a potential area of conflict. Originality/value This paper discusses potential benefits as well as risks of merging DFSS and LPD based on industrial experiences. Consideration of the differences addressed, by practitioners as well as academics, will contribute to a well thought‐out design of a merger of the two concepts.

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References

2009Building theories from case study research 2004Learning to evolve 1994MANAGEMENT THEORY AND TOTAL QUALITY: IMPROVING RESEARCH AND PRACTICE THROUGH THEORY DEVELOPMENT 2007Six Sigma: Definition and underlying theory⋆2002Quality management re‐visited: a reflective review and agenda for future research 2005The integration of lean management and Six Sigma 2008The evolving theory of quality management: The role of Six Sigma 1992The Hidden Costs of Accelerated Product Development

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