Design for Lean Six Sigma course supercharges your skills on designing new products, services or processes that can deliver quality and reliability.

Training Level



8 Days



Design for Lean Six Sigma (DFLSS) is a rigorous methodology that guarantees new product development process has a systematic approach: Customer satisfaction achieved by products with the correct functionality. Designs that meet the expectations of the products. Processes with results that meet the design specifications.

This 8-Day programme is ideal for design or process engineers who want to use the DFSS methodology to design or redesign products, services or production processes. The course is also of great value to Black Belts who want to improve the effectiveness of their NPD processes by using the tools & techniques of engineering design in the right way.

The Design for Lean Six Sigma course applies the popular DMADV (Define-Measure-Analyse-Design-Verify) methodology used by Lean Six Sigma practitioners around the world. Beyond traditional DFLSS approaches, we emphasise 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 organisation to generate optimal designs at a rapid pace and stay ahead of the market.

You’ll learn about the details of DFLSS in a focused workshop environment - complete with interactive group exercises and realistic simulations. While statistical design tools are an integral part of this course, the importance of defining and translating customer needs, financial and risk analysis, human-centred design and Lean service design techniques are also emphasised. In addition, the instructor will tailor content and examples to the composition of each class.

Facilitated by Master Black Belt-level instructors with years of Lean Six Sigma real-world NPD experience, this course uses a blend of theory and practical exercises to ensure participants have the confidence and capability to design or redesign products, services or production processes.



Black Belts or Master Black Belts who want to improve their product or service design skillsets.

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 emphasise either, or both.

  • Use DMADV, Lean and Innovation methodologies to complete new product and process development projects.

  • Identify DMADV and DMAIC project opportunities.

  • Complete project financial and risk analyses.

  • Design and analyse robust designed experiments.

  • Describe the elements of process and service roadmaps.

  • Predict output variability using techniques such as Monte Carlo simulations.

  • Predict service levels based on resource decisions.



  • Project Charters

  • Review of Teams’ Project Charters

  • Managing Product Development Progress

  • Understand Product Requirements

  • Converting VOC into Product CTQs

  • Measurement System Analysis

  • Functional Analysis

  • Finalising the QFD (1st House)

  • Generate Concepts I: Brainstorming & Lateral Thinking

  • Generate Concepts II:- TRIZ

  • Concept Selection

  • Risk Analysis

  • Preparation for Wave II: Deriving Design CTDs


  • Introduction to Minitab

  • Applied Statistics

  • Understanding Process Capability

  • Lean Service Design

  • Human-centred Design

  • Advanced Design of Experiments

  • Understanding Variation

  • Process CTPs 

  • Meeting Conflicting Targets

  • Pre- & Post-Pilot Actions

  • Reliability

  • Process Controls

  • Control CTCs

Exclusive Benefits.

  • Every course is taught by a Master Black Belt instructor with real world knowledge and extensive project experience

  • The Master Black Belt provides support and project consultation throughout the class

  • Professional quality, laser printed student manuals and quick reference guides

  • Online learning portal access for up to 12 months after training 

  • Valuable data files and templates that can be used for projects in the future

  • Sample case studies of DMADV projects

  • Useful Project Charter examples

  • On-site coaching and/or remote support by email/phone are offered at a special rate for all participating students