Design for Six Sigma and FMEA

Candidates seeking Six Sigma Green Belt certification; quality professionals, engineers, production managers, and frontline supervisors; process owners and Champions charged with the responsibility of improving quality and processes at the organizational or departmental level


Expected Duration
102 minutes

Design for Six Sigma (DFSS) is an innovative approach for the design or redesign of a process, product, or service from the ground up. It follows a ‘pay me now or pay me later’ adage by spending effort and time on creating a Six Sigma level process or product design up front, avoiding efforts to fix them later. Tools such as failure modes and effects analysis (FMEA) are extensively used to achieve DFSS goals. FMEA helps identify possible failures and their potential impact on a design, manufacturing assembly process, or product or service and prioritize actions to address them. This course will examine how Six Sigma combines DFSS and tools such as FMEA to reach its organizational goals. It introduces key DFSS and FMEA methodologies and concepts, distinguishes DFSS methodologies from Six Sigma DMAIC, and explains how to prioritize process and design risks using FMEA. This course is aligned to the ASQ Body of Knowledge and designed to assist Green Belt candidates toward their certifications and becoming productive members of their Six Sigma project teams.


Introduction to DFSS

  • match DFSS tools to their descriptions
  • determine whether to use DFSS for a given project
  • identify the similarities between DFSS and Six Sigma
  • demonstrate understanding of what DFSS is and when it’s best used

DFSS Methodologies

  • match stages in the IDOV methodology with corresponding activities
  • match stages in the DMADV methodology with corresponding activities
  • label characteristics as belonging to either DMAIC, DMADV, or IDOV
  • distinguish between DMAIC, IDOV, and DMADV in terms of characteristics and uses

Failure Modes and Effects Analysis (FMEA)

  • identify characteristics of FMEA
  • match types of FMEA with corresponding descriptions
  • recognize steps in the FMEA process
  • demonstrate your understanding of FMEA

Risk Priority Number

  • assign severity, occurrence, and detection ratings to a given failure mode
  • calculate the percentage reduction in RPN
  • complete and analyze an FMEA worksheet

Design FMEA and Process FMEA

  • distinguish between design and process FMEA
  • interpret information found in a given FMEA worksheet
  • complete and analyze an FMEA worksheet





Multi-license discounts available for Annual and Monthly subscriptions.