Complexity reduction in product design and development using Design for Six Sigma

Abstract

In this paper, we examine various aspects of complexity in product design and development, and propose a Total Cost of Complexity (TCC) equation to quantify the impact of non-value-added complexity. This paper attempts to conceptually link the complexity concepts to the Design for Six Sigma (DFSS) approach and looks at DFSS project types, project structure to match with complexity reduction efforts. We also discuss the DFSS project structure requirements for complexity reduction based on broad criteria and compare other kinds of structures against it. A model for DFSS evolution in an organisation is proposed covering various stages an organisation goes through during DFSS implementation. An automobile fluid connection case study clearly illustrates the DFSS approach to reduce component complexity and quantifies the benefits using the TCC equation.