Reducing Defects in System Design

A DFSS project was done to reduce the defect rates in the new HVAC system design. Initially, the design phase experienced a 15% defect rate, leading to increased rework costs of INR 1.2 lacs. The team implemented Design For Six Sigma methodologies and conducted a Voice of Customer (VoC) analysis. They redesigned critical components and introduced rigorous testing protocols. As a result, defect rates dropped to 5%, saving the company INR 3 lacs annually in rework and warranty costs. This project enhanced product reliability and aligned design processes with customer expectations.