Embedding Quality and Performance into the Design Rather Than Fixing Later
                     Embedding Quality & Performance 
Into The Design Rather Than 
Fixing Later
Using DFSS to Prevent Downstream Cost, Variation, and 
Operational Instability
www.bmgindia.com
Embedding Quality & Performance 
into the Design Rather Than Fixing 
Later
BMGI India, one of the leader in Design for Six Sigma, helps 
organizations embed quality and performance directly into their 
design phase. By using DFSS principles, businesses can 
prevent downstream costs, reduce variation, and ensure 
operational stability. This proactive approach prevents defects 
and minimizes the DPMO (Defects Per Million Opportunities), 
helping organizations improve both product and process quality 
from the outset.
Why DFSS Matters
Design for Six Sigma (DFSS) is crucial for preventing operational 
instability and controlling costs from the outset of product and 
process design.
• Embeds quality management in the design phase, reducing 
reliance on later fixes
• DFSS consulting helps organizations optimize designs for 
performance and reliability
• Reduces variation and ensures that designs meet customer 
expectations
• Helps improve DPMO, ensuring fewer defects and higher-
quality outputs
• Ensures alignment with operational goals and strategic 
priorities
What DFSS Achieves
Implementing Design for Six Sigma ensures a proactive 
approach to design.
• Helps organizations build robust designs that withstand 
market and operational pressures
• DFSS reduces the need for costly adjustments by addressing 
issues early in the process
• Integrates customer needs and performance goals from the 
very beginning
• Minimizes operational inefficiencies by focusing on design 
optimization
The DFSS Process
DFSS follows a clear, structured process to embed quality and 
performance into the design phase:
• Define: Identify customer requirements and convert them 
into actionable design specifications
• Measure: Establish metrics to track design success, 
including DPMO to track defects
• Analyze: Evaluate potential risks and areas for 
improvement using FMEA (Failure Mode and Effect Analysis)
• Design: Create and test prototypes that meet performance 
objectives
• Verify: Confirm that the design meets customer needs and 
operational requirements before full-scale production
Key Benefits of DFSS
By embedding quality and performance in the design phase, 
BMGI India  helps organizations:
• Prevent costly rework and adjustments later in the process
• Improve operational efficiency through robust designs that 
meet requirements
• Reduce variation and enhance process consistency
• Ensure sustained improvements in product performance and 
customer satisfaction
• Achieve lower DPMO, ensuring higher product quality and 
reliability
•  It should be BMGI India
DFSS Tools & Techniques
DFSS utilizes various tools and techniques to drive 
successful design outcomes:
• FMEA to identify and mitigate potential failure modes 
early in design
• Design of Experiments (DOE) for optimizing design 
parameters and ensuring reliability
• Quality Function Deployment (QFD) to translate 
customer needs into precise technical specifications
• Six Sigma metrics to measure design performance, 
including DPMO for assessing defects
• Robust Design to ensure the product performs well 
under varying conditions.
Case Study: DFSS In Action
Client: A leading manufacturing company
Challenge: High defect rates and operational inefficiencies in product 
design
BMGI India’s Role:
• Applied Design for Six Sigma methodologies to improve product 
design and processes
• Conducted root-cause analysis using FMEA to identify design risks
• Used DOE to optimize key design parameters and improve 
performance
• Delivered DFSS consulting to help the company sustain continuous 
improvements
Outcome:
• 25% reduction in defects and design revisions
• Improved product quality and reliability
• Lower DPMO and increased customer satisfaction
Why Choose BMGI India
BMGI India offers expertise in embedding quality and 
performance into the design phase sing DFSS methodology:
• Proven track record in implementing Design for Six Sigma 
across industries
• Expertise in Six Sigma and Lean methodologies to optimize 
design and operational processes
• Tailored approach to meet client-specific needs and drive 
sustained improvement
• Focus on achieving long-term operational excellence and 
cost optimization through DFSS
Conclusion
BMGI India helps businesses integrate Design for Six Sigma 
principles early in product and process design to ensure 
operational stability and reduce downstream costs. With our 
DFSS consulting expertise, we help organizations develop 
robust, high-performing designs that meet customer 
expectations and improve operational efficiency.
Breakthrough Management 
Group
India Private Limited
Location: 905/906 Raheja Chambers, 213 Nariman Point,
Mumbai, Pin-400021, India
Phone: +91 22 4002 0045/46 |  Email: [email protected]