Abstract

Design for Six Sigma (DFSS) is a product development approach that complements Six Sigma problem solving methodology. Many companies developed their own DFSS processes before a standard template became available, but all versions share fundamental strategies and tools. Ford Motor Co. developed its program in 1999 with emphases on the training of black belts and the completion of DMAIC projects. Implementation began at Ford's Powertrain Division, but soon other divisions were launching DFSS as well. Issues with training and execution of projects highlighted assumptions that required reevaluation, including DFSS rationale, project integration, process flexibility, and training. DFSS implementation at Ford showed the challenges to be more cultural and organizational than technical. DFSS at Ford has emerged as an enhancement to the present product development system that reinforces the company's Six Sigma skill base.