Design for Six Sigma Black Belt Course Code : S-08

Duration : 4 weeks spread over 4 months

Introduction :

Conventional Process Six Sigma Approach works very well when the process is repeatedly used. However, when we introduce new products, this is not the case. Thus the DMAIC approach is not appropriate to assure that new products meet or exceed customer requirements, are reliable and competitive. Bob Galvin, former CEO of Motorola stated that if he would start six sigma again, he would focus on design rather than manufacturing. Design for Six Sigma (DFSS) is more appropriate and offers more powerful tools better suited to introduce reliable new products which perform to customer expectations. The DMAIC approach does not offer any major tools to evaluate and improve reliability. Define-Measure-Analyze-Design-Verify/Validate (D-M-A-D-V) roadmap of DFSS offers  tools for understanding customer expectations, robust design, statistical Tolerancing and Reliability Assessment/Prediction.  Most companies realize that the Process Six Sigma approach is not adequate to cross a “5-Sigma Wall”. They find that many of the defects and failures are "designed in."

Who should attend the training?
The course is most appropriate for engineers and project leaders responsible for introduction, design and development of new products and processes.

Benefits of the training :
After attending the workshop, the participants will be able to understand and apply DFSS tools to design and develop better and more reliable new products. They will be able to :
Identify DFSS vs. DMAIC projects. Participants would also be able to design and analyze a Robust Design of Experiments (DOE), complete a product tolerance analysis including Monte-Carlo Simulation. This 4-week training workshop organized by Institute of Quality and Reliability (IQR) includes sufficient hands on exercises using Minitab software and About 30% time in the workshop would be dedicated to the application exercises. After each week of training, participants go back to their work and apply the tools to their projects. Thus the training is distributed over four months, one week every month. Projects will be reviewed every week for progress and guidance for use of appropriate tools.

Structure of Design for Six Sigma training workshop :
The four-week training agenda focuses on learning the concepts and immediately applying these to the projects selected by the participants. Class exercises are designed specifically to enable retention and application to the projects.

Course Contents :
Week 1

  • DFSS Overview and understanding value
  • Developing the business case and defining projects
  • APQP and Project Management overview
  • Market Segmentation, Kano Model
  • Finding cognitive images with KJ, Kano Surveys
  • Converting Cognitive Images in to CTQs using Quality Function Deployment (QFD)
  • Concept Generation and Pugh concept selection,
  • Introduction to Critical parameter management (CPM)

Week 2 :

  • House of Quality for the next level and CPM
  • Developing and Validating Measurement System Subsystem
  • Introduction to Minitab
  • Basic statistics, Graphical analysis of data,
  • Measurement Systems Analysis
  • Design FMEA ( DFMEA )
  • Process Capability Analysis
  • Design for Manufacturing and Assembly ( DFMA ), C-E matrix
  • Statistical Tolerancing,
  • Monte Carlo simulation,
  • Project Reviews

Week 3 :

  • Hypothesis testing, Confidence intervals, t-tests
  • Multi-Vari Studies
  • Analysis of Variance (Anova) : Balanced, General Linear Model.
  • Correlation, Simple and Multiple Regression.
  • Introduction to Design of Experiments (DOE),
  • Full and Fractional Factorials, Factorial Designs
  • Fractional Factorial Designs,
  • Project Reviews

Week 4 :

  • Component Manufacturing Process House of Quality / CPM
  • Response surface methods and Multiple Response Optimization.
  • Robust Design and Taguchi Methods
  • Life Data Analysis
  • Reliability Testing and Sample Size
  • Accelerated Life Testing and HALT
  • Multiple Environment Stress tests (MEOST)
  • Statistical Process Control
  • Closing remarks and wrap up

Faculty :
Mr. Hemant Urdhwareshe is Director, Institute of Quality and Reliability (IQR). He has more than 28 years of experience in Manufacturing, Quality and Engineering at Cummins India Limited (CIL). As head of quality, reliability and subsequently engineering functions at CIL, he was actively involved in driving Six Sigma and has sponsored many Six Sigma projects. He has applied various Six Sigma tools in improving processes and solving complex manufacturing and field problems. He has conducted many in-house training programmes on Leadership, Quality Engineering and management at CIL and on behalf of Indian Institution of Production Engineers (IIPE), Pune Section. He has also published many articles on Six Sigma and quality engineering.

He has conducted Black/Green Belt Programmes for Fleetguard Filters, TACO, Alfa Laval, Menon Pistons and DGP Hinoday. He has also conducted Six Sigma Green Belt public workshops.

He is :

  • The first ASQ Certified Six Sigma Black Belt in India
  • The first ASQ Certified Quality Manager in India
  • ASQ Certified Quality Engineer and
  • ASQ Certified Reliability Engineer
  • The only person in India with four or more certifications from ASQ
  • Recipient of Silver Standard 2003 award from Qimpro Foundation
  • Senior Member of ASQ, Fellow of IIPE and member of National Center for Quality Management. (NCQM).
  • Qualified Lead Assessor

Hemant Urdhwareshe will be supported by Dr.Vikas Garud.
Dr. Vikas Garud is working in area of Quality Management throughout his career, spanning over 20 years. He is a mechanical engineer from VJTI, Mumbai University. He completed post graduation – M. E., with specialization in Machine Design. His project in Robotics area was instrumental in development of full fledged robotics and automation laboratory in VJTI. He was first in the batch, in Mumbai University. Combining professional experience and research work carried out for the Aeronautical R&D Board, Defense Ministry, Govt. of India, he successfully completed Ph. D. in the area of Design Quality Assurance from Mumbai University. Dr. Vikas Garud started his career in Quality Management in MIRC Electronics Ltd., makers of the Onida brand of home appliances. Dr.Garud has assisted many organization in developing quality systems and preparing for Business Excellence Awards. He has conducted number of workshops on QFD, FMEA, SPC, MSA, Process Mapping, Quality Audits Problem Solving and Six Sigma.

Course Material :
Comprehensive workshop material by IQR with appropriate exercises using appropriate software and templates.
Catapults and other material for exercises will be arranged by IQR.

Contact us :
Institute of Quality and Reliability,
Plot No.39,
Shantiban Cooperative Housing Society,
Near Gandhi Bhavan,
Pune 411029.

Phone : 91-20-25367952
Email :
Web site :

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