IDOV is a commonly used Six Sigma methodology and stands for Identify, Design, Optimize and Verify. It is a variant of DFSS or Design For Six Sigma, which is used for designing a completely new product or business process to meet customer needs and specifications or to achieve Six Sigma quality levels. As a methodology, IDOV is very different from DMAIC or define, measure, analyze, improve and control, which is used only for optimizing the existing products or business processes. IDOV consists of four different phases described below:

Identify Phase

The identification phase deals with identifying specific customer needs, based on which a product or business process will be designed. Proper identification of customer needs is very essential for launching a new product or service. In this phase, Six Sigma professionals are required to define VOC or voice of the customer, develop a team and team charter, perform competitive analysis and identify CTQ or critical-to-quality factors.

Some of the most crucial steps in this phase involve the identification of customer and product requirements, establishment of an appropriate business model, identification of technical requirements such as CTQs, allocation of roles and responsibilities and setting up milestones or benchmarks. Some of the main Six Sigma tools used in this phase include QFD or quality function deployment, FMEA or failure means and effects analysis, SIPOC or supplier, input, product, output, customer product map, IPDS or integrated product delivery system, target costing and benchmarking.

Design Phase

The design phase deals with various issues such as functional requirements, development of alternate business processes, evaluation of available options, and selection of the most appropriate business process, based on CTQs that were identified during the first phase. The design phase involves the formulation of concept design, identification of probable risk elements, identification of design parameters by utilizing advanced simulation tools and formulation of procurement plans and manufacturing plans. Some of the main Six Sigma tools used in this phase include smart simple design, risk assessment, FMEA, engineering analysis, materials selection software, simulation, DOE or design of experiments, systems engineering and analysis tools.

Optimize Phase

This phase utilizes CTQs for assessing the tolerance level of a selected business process, with the help of advanced simulation tools. This phase is used for predicting the performance capability of a business process, optimizing existing design and developing alternative design elements. This phase may involve assessment of process capabilities, optimization of design parameters, development of design for robust performance and reliability, error proofing and establishment of tolerance measurement objectives. Some of the most common tools used in this phase include manufacturing database and flow back tools, design for manufacturability, process capability models, robust design, Monte Carlo methods, tolerance measurement tools and Six Sigma tools.

Validate Phase

The last phase of IDOV methodology deals with testing and validating the selected design. Changes to a business process design can be made in this phase. Some of the main steps in this phase include prototype test and validation, assessment of performance, failure modes, reliability and risks, design iteration and final phase review.