S-06_Six Sigma

Design for Six Sigma Green Belt

Duration : 6 days spread over 2 months


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. Concept-Design-Optimize-Verify (CDOV) 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. The training is designed to inculcate statistical thinking in designing and developing new products. They will be able to apply tools such as  

  • Quality Function Deployment (QFD)

  • Measurement Systems Analysis

  • Process Capability Evaluation

  • Design and Analysis of Experiments (DOE) for robust design,
  • Statistical Tolerance Stack-up Analysis using Monte Carlo Simulations
  • Life data (reliability) analysis
  • Statistical Process Control 

This 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 part I of training, participants go back to their work and apply the tools to their projects. Thus the training is distributed over two months, 3 days for two months. Some time is usually devoted for Project Selection in part I and project discussions in part II.

 Structure of Design for Six Sigma training workshop:

The training agenda focuses on learning the concepts and applying these to the projects selected by the participants. Class exercises are designed specifically to enable retention and application to the projects.


Mr. Hemant Urdhwareshe is Director, Institute of Quality and Reliability (IQR). He has about 30 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 has trained more than 100 Black and Green Belts. His article on Cricket and Sigma in Marathi was recently published in daily “Sakal”.

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 other competent faculty.

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 organizations 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.

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