The Engine Room of Continuous Improvement

Design for Six Sigma (DFSS) Courses

Design for Six Sigma (DFSS) Courses

Cost Curve Chart


This course covers the complete Design for Six Sigma (DFSS) body of knowledge, including both product and process design.

We offer two DFSS courses for experienced Lean Six Sigma Practitioners: Product Design (50 hours) and Process / Service Design (40 hours)

Select a version below to customize your course description.


      Product Design            Process / Service Design

The Product version includes additional lessons on advanced statistics and experimental design. Both versions use the D-C-D-O-V roadmap.

  • Course Overview +

      Design for Six Sigma (DFSS) is not a methodology in and of itself. Rather, DFSS is a set of best practices and tools which, when integrated into a product / service development process, increases your organization's ability to meet your customers' requirements in a timely, cost-effective manner.

      As the name suggests, DFSS is about design. DFSS saves costs in part because the cost of making a change increases exponentially during the lifecycle of a development project (as shown above).

      When you have completed this course, you will have a solid general knowledge of the tools, methods and best practices necessary for developing products and processes that can meet Six Sigma levels of quality.

      Learning Objectives

      The overall objective of this course to introduce you to the best practices and methodologies that are essential for developing product or process designs that meet customer requirements at the highest possible level of quality.

      • Communicate using Design for Six Sigma concepts.
      • Identify areas within your existing development process where DFSS is needed.
      • Integrate DFSS into your existing development process.
      • Select optimal product or process design concepts.
      • Use analytical and experimental methods to develop robust and reliable designs.
      • Modify designs for optimal performance based on variability of the inputs and desired outputs.
      • Verify that the designs meet the requirements at the desired level of performance.
      • Employ your DFSS skills to lead a successful development project delivering meaningful results to the organization.

      To successfully complete this course, you must review all of the lessons and complete all of the quiz modules.

      Course Structure

      DCDOV cycle

      This course consists of six sessions, each of which is a collection of related lessons.

      Individual lessons also include simulations, toolsets and interactive practice exercises. Each session ends with an interactive quiz to test your knowledge.

      The course is presented in a logical sequence to follow the Define-Concept-Design-Optimize-Verify (DCDOV) representation of DFSS.

      At the core of the course are the principles of understanding customer requirements, translation of requirements (QFD), design concept generation and evaluation, and development of predictive transfer functions.

      The DFSS course also covers design optimization, robust design, and incorporates some Lean concepts (e.g., continuous flow, identifying waste, value stream maps) for Design for Lean Six Sigma (DfLSS). Process Playground™, MoreSteam's online discrete simulation tool, is now available for free in the Optimize session of both versions of the DFSS course.

      On every page, you have access to a variety of helpful learning tools, from an online encyclopedia to a notes tab to support links. You can use the course navigation map to move through the course in a linear fashion or you can skip around and explore topics as you see fit.

      Want to see what the course looks like? Then take our brief course tour.

      Applying this Course to Your Work

      It is important to understand that the DFSS course itself does not represent a generic development process. The course is laid out as a process to facilitate orientation to your organization's own development process.

      After going through the course and understanding the purpose and application of the various tools, methods and best practices, you should compare the content of the course to the tools, methods and best practices in your organization's development process.

      This process of comparison will highlight gaps between your organization's process and its potential as a DFSS development process. You will then be able to close the gap by integrating the missing material into your organization's process.

      Efficient, Informative and Accessible

      • All course content is presented online, in an on-demand format. To begin, you simply log onto the MoreSteam University learning portal.
      • Numerous case studies and examples focus on service and transactional processes, as well as production applications.
      • With a heavy practice orientation, as much as 1/2 of your time will be spent working through interactive practice exercises and online assessments.
      • You have 270 days to complete this course.
  • Is This Right For You? +

      Magnifying glass
    • Are you an engineer, programmer or process designer?
    • Do you need to create new products or services?
    • Then this course is right for you. In either version, you not only discover and learn the core concepts of DFSS, but you gain experience and competence as you apply them to the course project simulation.
    • Online training is ideal if you have limitations on your time, travel, and budget, especially if you've been asked to work your day-to-day job at the same time you need to learn DFSS.
    • Our courses provide you with content-on-demand, which means you can set your own schedule, progress at your own speed, and review and re-enter sessions whenever you wish. It's flexible, practice-based, and accessible whenever and wherever you need it.
  • Benefits +

      Online training through MoreSteam is:

    • Flexible: This course is presented in a logical, DCDOV format, but the sessions are modular, so you can explore the material as, how, and when you like. Alternate design roadmaps are also available to corporate clients.
    • Accessible: Online training is available to you wherever you have an Internet connection and a browser.
    • Responsive: The quizzes provide immediate feedback. The practice-based interactive exercise will engage your interest and help you to remember the material.
    • Affordable: e-Learning has a far lower cost than classroom training. You have no travel expenses and don't miss valuable days at work.
    • Meaningful: As proof of your expertise, you will receive a certificate of completion and CEUs or PDUs of credit.
  • What the Alumni Say +

    • Selected recent quotes from our alums:
    • "An excellent vehicle for learning and applying the principles of Design for Six Sigma, process and product."
    •     - James B.
    • "This was a really fun way to learn. The materials will be a great reference. The tools are wonderful."
    •     - Nancy T., SMDC Health System
    • "MoreSteam has done an outstanding job of making the "DFSS for Process" training a meaningful experience. They clearly understand how to deliver quality training because they recognize that requires BOTH excellent material AND knowledge of the delivery medium."
    •     - Chad J., TRW Automotive
    • "I found this course to be very up-to-date in its thinking, and it has a very high relevance of reference material."
    •     - Jim H., Tecnotree Limited
  • Course Outline +

      Session 1: Introduction
      Design for Six Sigma Introduction
      Closing the Gap
      Better Aim Through DFSS
      Improving Lifecycle Cost
      DFSS and DMAIC
      What is Design for Six Sigma?
      The Alphabet Soup of DFSS
      Process Phase-Gates
      Design Leverage
      How To Use This Course
      Keeping Track of Where You Are
      DFSS Achievements
      Exercises and Quiz
      Session 2: Define
      Introduction
      Project Selection Toolset
      Project Charter Toolset
      Project Tracking Toolset
      Obtaining the Voice of The Customer
      Market Segmentation
      Understanding Customer Requirements
      Listening to All the Voices
      Where to Go For Customer Requirements
      Conducting Surveys
      Survey Considerations
      Surveys - Sampling Frame
      Structuring Survey Questions
      Affinity Diagram Toolset
      CTQC Tree Diagram Toolset
      Operational Definition Toolset
      Voice Of The Customer As Specifications
      Progress Review
      Exercises and Quiz
      Session 3: Concept
      Introduction
      QFD Toolset
      Metrics
      The Core Principle of DFSS
      Process Capability Toolset
      Benchmarking
      Beyond Customer Requirements
      Brainstorming
      Encouraging The Creative Process
      Narrowing Down The List of Ideas
      Pugh Concept Selection Toolset
      Progress Review
      Exercises and Quiz
      Session 4: Design
      Introduction
      Design Development
      Results By Design
      Design Scorecard
      Analyzing Designs
      More on QFD
      Correlation and Regression Analysis
      Multiple Regression Toolset
      Error-proofing
      FMEA Toolset
      Product and Process Reliability
      Basic Reliability Calculations
      Transfer Function Toolset
      Progress Review
      Exercises and Quiz
      Session 5: Optimize
      Introduction
      Building a Process Model
      From Process Diagram to Process Model
      Predicting Process Performance With Simulation
      Process Playground - Online Discrete Event Simulation
      Monte Carlo Toolset
      Tolerance Design & Optimization Toolset
      Optimization
      Response Surface Methods
      Optimization with Response Surface Methods
      Continuous Flow Optimization Toolset
      Design For Lean - Supply Chain Dynamics
      QFD: Building The Fourth House
      Progress Review
      Exercises and Quiz
      Session 6: Verify
      Introduction
      Other Aspects of Verification
      The Process Control Plan
      Testing a Design
      Achieving Reliability Through Testing
      Robust Design and Taguchi Methods
      Minimum Run Resolution V Designs Toolset
      Robustness Testing Practice
      Piloting a Design
      Launch
      Evolutionary Operation Toolset
      Ending a Project
      Progress Review
      Exercises and Quiz
      Course Completion
      The Lean Six Sigma Journey
  • Pre-Requisites +

    • This course (both versions) assumes that you have previously mastered at least the Six Sigma Green Belt body of knowledge, specifically Measurement System Analysis and Multiple Regression Analysis.
    • Service Version: If you have not mastered this body of knowledge, we recommend that you first enroll in the Lean Six Sigma Green Belt course, which will provide appropriate preparation.
    • Product Version: You will also need to understand basic Design of Experiments (DOE) for this version. If you have not mastered this body of knowledge, we recommend that you first enroll in the Lean Six Sigma Black Belt course, which will provide appropriate preparation.
  • Materials +

    • Materials Provided by MoreSteam

    • Both Versions

    • Microsoft® Excel® templates for statistical analysis, available as downloads within the course material.
    • Process Playground™, MoreSteam's online discrete simulation tool, is now available for free in the Optimize session of both versions of the DFSS course.
    • Product Version Only

    • Design-Expert Software for Design of Experiments by Stat-Ease (a $995 value)
    • Mark J. Anderson and Patrick J. Whitcomb, RSM Simplified - Optimizing Processes Using Response Surface Methods for Design of Experiments (Productivity, Inc. 2005). ISBN: 1563272970
    • IMPORTANT NOTE: The DOE software, RSM Simplified book, and Roller Coaster Tycoon will be shipped to your mailing address within two weeks of starting the course. Non-U.S. Customers: Please note that you will be responsible to pay any local customs duties or taxes. The value of the software and book is approximately $1150. The value of the Roller Coaster Tycoon software alone is approximately $25. A memo invoice will be included in the shipment for customs purposes.
    • Materials Provided by Student/Company

    • General-purpose Statistics Software is useful but not necessary. Excel templates are provided by the course for statistical analysis. If you do not have a statistics package, options range from free internet downloads to higher-end packages like EngineRoom®, Minitab®, Statistica®, JMP® etc. You can download a 30-day evaluation copy of most statistics packages over the Web.
    • Microsoft Office (Word, Excel, Powerpoint). Office 2007 or higher is recommended. Older versions of Excel do not support all MoreSteam template features.
    • Optional Materials:

    • Microsoft Project, Microsoft Visio®
    • Rath & Strong's Six Sigma Pocket Guide (Rath & Strong, Inc; Spiral edition, October 17, 2000) ISBN: 0970507909
    • Greg Brue, Robert G. Launsby, Design for Six Sigma (Massachusetts Institute of Technology, Center for Advanced Engineering Study 1982, 1986) ISBN: 0071413766
  • Support +

      When in your training course, you can use the on-screen Help features (e.g., glossary of terms and site search) for information. You can contact the Course Instructor by email during regular business hours to request assistance.

      For general technical support, you can visit our MoreSteam University support section, where you can search through our online knowledgebase or send us a support request.

  • System Requirements +

    • The following are system requirements for MoreSteam eLearning:

      • Operating System: Microsoft Windows (7 and higher) or Apple Mac OS X
      • Microsoft Office®: English-language (U.S.) version 2007 or higher.
        • Network: Microsoft Excel must be running locally. EngineRoom will not perform correctly if you are running Microsoft Excel over a network as a distributed application.
        • Versions: Only one version of Microsoft Excel can exist. EngineRoom will not perform correctly if there are multiple versions of Microsoft Excel installed on a single computer.
        • Macro Security: EngineRoom contains macros; therefore Microsoft Excel macro security must be set to medium or lower.
        • Toolpaks: The Microsoft Excel Analysis Toolpak and Analysis Toolpak VBA must be installed.
      • Display Properties Setting: Minimum 1024 x 768 screen resolution.
      • Audio: Optional audio in course.
      • Browser:
      • Adobe Acrobat Reader: Latest version
      • Flash 10 Player: Latest version
      • Note: The course content requires that any pop-up blocker be disabled.

Common Questions

When can I begin the course?

With e-Learning, you can start at any time after purchase. You do not have to wait for other students to fill a class or have to attend an instructor-led "kickoff" event. All the materials and instructions are online, and you can complete the course at your own pace.

Does this course include certification?

We do not offer a formal certification for our short courses. As proof of your training, you receive a formal certificate of completion when you pass all of the course quizzes. You also receive CEUs or PDUs of credit.

Do you offer pricing discounts for groups of trainees and deployments?

Of course! Many of our larger customers send tens to hundreds of employees through DFSS training. Please contact us directly to discuss your specific needs.