Key Steps to Designing High-Quality Products: Identify, Design, Optimize, Validate

In this discussion, we will delve into the IDOV methodology, a technique associated with Design for Six Sigma (DFSS). We will compare IDOV to other DFSS approaches, highlight its benefits, and offer recommendations for enhancing its effectiveness.

Summary: What does IDOV stand for?

Six Sigma is a philosophy and methodology that aims to improve all processes in your organization. The primary approaches and methods include DMAIC (Define, Measure, Analyze, Improve, Control) and DFSS.

DMAIC focuses on steadily improving processes, whereas DFSS is centred on significantly redesigning products or processes to reach defect-free or Six Sigma quality standards.

The DFSS framework encompasses different methodologies, each with its unique definition, but all follow the same fundamental process. Here are the four most frequently used approaches and a comparison to DMAIC.

1. DMADV: Define, Measure, Analyze, Design, Verify

2. DMADOV: Define, Measure, Analyze, Design, Optimize, Verify

3. DMEDI: Define, Measure, Explore, Develop, Implement

4. IDOV: Identify, Design, Optimize, Validate

Further details on IDOV:

Identify Phase:

The Identify phase starts by linking the proposed design requirement to the voice of the customer (VOC). During this phase, a team will be formed, a project charter will be established, the voice of the customer will be gathered, competitor benchmarking will be carried out, and critical-to-quality characteristics (CTQs) will be defined.

Items to be delivered during the IDENTIFY phase:

• Determine the specific customer and the requirements associated with the process or product.

• Compose your business case.

• Develop specifications for your Critical-to-Quality requirements to identify technical requirements.

• Define roles and duties and create a RACI (Responsible, Accountable, Consulted, Informed) chart.

• Create schedules and set specific goals to achieve.

Design Phase:

The design phase aims to identify product functional requirements, explore alternative concepts, and select the most suitable concept, all based on the Critical to Quality (CTQ) parameters. Predicting the sigma level is essential to achieve the desired Six Sigma or defect-free quality level.

Items to be delivered during the DESIGN phase:

• Finalize the concept design.

• Discover possible risks and mitigation tactics using Failure Mode and Effects Analysis (FMEA).

• Identify specific design parameters for every technical requirement.

• Create a strategy for acquiring necessary raw materials or components.

• Develop a plan for any needed raw material or component acquisition

• Production strategy

• Utilize statistical techniques like DOE (design of experiments) to establish the correlation between CTQ characteristics and your technical specifications.

Optimize Phase:

During the optimization phase, it is essential to have data on process capability and to utilize statistical methods for tolerancing. This stage involves creating specific product design components, forecasting performance, and refining the ultimate design. By conducting process capability analysis, suitable design tolerances can be determined.

Items to be delivered during the OPTIMIZE phase:

• Evaluate the process capabilities to ensure they align with critical design parameters and CTQs.

• Create a design that ensures robust performance and dependability across diverse conditions.

• Implementing Poka Yoke, also known as error-proofing, aims to prevent mistakes from occurring.

• Calculate tolerance boundaries

• Optimize your sigma level while reducing development expenses.

Validate Phase:

During the validation phase, the activities include testing, piloting, and validating the design. 

Items to be delivered during the VALIDATE phase:

• Test a prototype, conduct a pilot study, and validate if the design requirements can be fulfilled.

• Evaluate performance, potential failure modes, reliability, and risks.

• Make necessary design and redesign modifications as required.

• Final project evaluation, approval, and a quality assurance strategy

Advantages of IDOV:

1. Capturing the customer's feedback and important quality aspects.

2. Design with process capability in mind

3. Assessment of risk