Design for Lean Six Sigma (DFLSS)

An ounce of prevention is worth a pound of cure

Certification Requirements

About Design for Lean Six Sigma (DFLSS)

Design for Lean Six Sigma (DFLSS) is a powerful methodology for ensuring the quality and reliability of new product and process designs that exceed current market maturity levels or break into entirely new markets. Also known as Design for Six Sigma (DFSS), it can be applied across many environments.

This course focuses on product design and manufacturing or any process that produces a tangible product, including mining, refining, chemical and polymer processing, and energy production. (For a focus in other environments, such as services, financial, healthcare, research, business model and startups, we recommend our Innovation and Design Tools course.)

The Design for Lean Six Sigma course applies the popular DMADV (Define-Measure-Analyze-Design-Verify) methodology used by practitioners around the world.  Beyond traditional DFLSS approaches, we emphasize the often-missing element of front-end innovation to truly understand customer needs and how to translate those needs into design parameters. Participants also learn how to apply Lean thinking to new product design and development processes, enabling your organization to generate optimal designs at a rapid pace and stay ahead of the market.

Design is a truly cross-functional undertaking, not the sole responsibility of the product development function. While statistical design tools are an integral part of this course, the importance of defining and translating customer needs, financial and risk analysis, Lean manufacturing and assembly techniques, maintainability and sustainability are also emphasized.

You’ll learn about the details of DFLSS in a focused workshop environment—complete with interactive lectures, group exercises and individualized mentoring on real, problematic data sets and projects that you bring to class. Additionally, the instructor will tailor content and examples to the composition of each class.

Learning Objectives

Upon completion of this course, participants will be able to:

  • Understand how design for Lean (DFLSS) and Design for Six Sigma (DFSS) overlap and when to emphasize either, or both.
  • Use DMADV, Lean and Innovation methodologies to complete new product and process development projects.
  • Discern between DMADV and DMAIC project opportunities.
  • Describe the objectives of each DMADV phase.
  • Complete a project financial and risk analyses.
  • Analyze a Quality Function Deployment.
  • Select concepts based on a Pugh Matrix.
  • Complete a design scorecard.
  • Design and analyze a robust designed experiment.
  • Describe the elements of a process and the transactional roadmap.
  • Predict output variability using techniques such as Monte Carlo simulations.
  • Analyze reliability data.
  • Predict service levels based on resource decisions.
  • Describe the principles of Design for Manufacturer and Assembly
  • Define inventory policies based on desired service levels.
  • Select appropriate maintenance strategies for products.


What is the price of this training and education?





What is the length?

5 consecutive days, 36 hours of instruction

How many CEUs are available?


Who is this training and education appropriate for?

Product development and R&D professionals
Candidates in the Lean Methods Group Master Black Belt Development program
Six Sigma green belts, black belts and Lean project leaders.

Are there any prerequisites?


Laptop computer running Minitab and Microsoft Excel
Basic understanding of statistics

Does this course count as one of the electives for the Master Black Belt and Lean Master programs?

Design for Lean Six Sigma is an elective course for Master Black Belt but not for Lean Master.  


View the Complete Agenda

Day one
  • DFLSS Overview
  • Product and Process Design Methodology
  • Project Risk Analysis
  • Design Financial Analysis
Day two
  • Job To Be Done
  • Outcome Expectations
  • Translating Needs into Design
  • Generating Innovative Concepts
Day three
  • Concept Selection (Pugh Matrix)
  • Lean Design Principles
  • Mistake Proofing
Day four
  • Robust Design
  • Tolerance Design
  • Flow
  • Design FMEA
Day five
  • Prototyping and Piloting
  • Synchronization and Lean
  • Getting Started with DFLSS



I had hit a wall with DMAIC... with DFLSS I now have a new arsenal of new tools for breakthrough.

Dean Kounelis - Master Black Belt, Siemens VDO Automotive