Design for Six Sigma is a methodology that commonly uses DMADV roadmap. Here is a DMADV sequence that led to a spectacular failure.
D – Define – In the US, car fuel economy standards and car fuel emission norms present a design contradiction. If a car maker is excellent with emission norms, it is hard to meet fuel economy expectations. The goal of this DMADV project is to meet both the needs.
M – Measure – Detailed correlation studies indicate that better emission controls create adverse impact on torque and acceleration which affects driving experience. This means great driving experience affecting car sales and feedback is inversely affected by good emission controls.
A – Analyze – Emission controls are assessed for effectiveness during pollution tests that are conducted just once every two years. This test is done when pedals are used but the car steering is not in use.
D – Design – Modify the car software to activate emission control mechanism so as to ensure clean exhaust during testing. When on road, with steering in use, the software de-activates pollution controls and allows emission of pollutants beyond norms. This provides good driving experience and great feedback leading to more sales. As software is protected and it is illegal to fiddle with software, even lawmakers cannot read into the trick.
V – Validate – Test, retest and validate the software. Check in pilot tests, in real samples, in mass production. If it works well, launch it.