I understand that six sigma is ideally applied to processes where there is obvious benefits in terms of customer satisfaction, cost savings, etc., and where data is available so improvements are readily feasible. DFSS applies to new product or process development stages.

Has anyone had experience in applying six sigma methods to a new product launch during pilot stage, without prior DFSS? What I am saying is, just prior to full mass production of a new model/design, without customer feedback and limited production statistics, what would be the best way to apply six sigma methods? The objective of this question is to reduce the possible faults built into the new product from design and/or new manufacturing processes.

Your advice would be most appreciated,
Johnny

Any six sigma guru's have any comments with respect to this fella's question?