Written by David Rodgers

Manufacturing Quality Perspective

Written by David Rodgers, Lean Six Sigma Black Belt and ASQ-certified manufacturing quality leader with experience in enterprise storage hardware, quality systems, process improvement, training, and production operations.

Last editorial review: September 24, 2026. Reviewed for statistical accuracy, shop-floor practicality, and educational clarity.

The guides on SixSigmaKaizen.com are written from practical manufacturing experience and are intended to help teams apply Lean, Six Sigma, quality engineering, training, and operations methods more effectively in real production environments.

  • Lean Six Sigma Black Belt
  • ASQ CQE
  • ASQ CMQ/OE
  • Manufacturing leadership
  • Training and operations

Quality is what the customer says it is, but customers rarely say it in a form you can measure. The voice of the customer is the discipline of gathering what customers want, in their words, and turning it into requirements a team can design to.

This guide covers the main sources of customer input, how to translate it into critical-to-quality characteristics, and the Kano model, which sorts features into must-be, performance, and attractive categories. A worked example classifies four features of a cordless tool from survey data.

Open the Kano Analyzer Open the CTQ Tree Builder

Why the Voice of the Customer Matters

Quality Is Defined by the Customer

A product that meets every internal spec can still fail if it misses what customers actually value.

Requirements Are Rarely Stated Well

Customers say what they want in their own words. Someone has to turn those words into measurable requirements.

Features Are Not All Equal

Some features are expected and only noticed when missing, some raise satisfaction in proportion, and some delight. Kano's model tells them apart.

Prioritization Needs Evidence

Limited budgets mean choosing. Customer data keeps the choice from being the loudest opinion in the room.

Gathering the Voice of the Customer

SourceWhat it gives youWatch out for
Interviews and site visitsDeep understanding of context and unstated needsSmall samples; interviewer bias.
SurveysNumbers across many customersLeading questions; low response.
Complaints and returnsWhat fails in real useOnly unhappy customers who report.
Warranty and service dataFailure patternsLag between cause and data.
Observation (gemba)What people actually doRequires time and access. See the Gemba Walk Guide.

Then translate what customers said into requirements you can measure. "It should not die in the middle of a job" becomes a Critical-to-Quality (CTQ) characteristic such as runtime per charge, with a target and a tolerance. See Voice of the Customer and Critical to Quality.

The Kano Model

Noriaki Kano's model (1984) classifies features by how they affect satisfaction:

CategoryIf presentIf absentExample
Must-be (basic)Nobody notices; it is expectedStrong dissatisfactionA phone that makes calls
One-dimensional (performance)More is betterLess is worseBattery life
Attractive (delighter)DelightNobody noticesA feature nobody expected
IndifferentNo effectNo effectA feature nobody cares about
ReverseSome customers dislike itSome prefer withoutToo many settings

Over time, delighters become performance features and then must-be features, as expectations rise. That is why the survey must be repeated.

The Kano Survey

For each feature, ask two questions: how would you feel if the product had the feature (functional), and how would you feel if it did not (dysfunctional)? Each answer is one of: I like it, I expect it, I am neutral, I can live with it, I dislike it. Combine the two answers using the evaluation table:

Functional \ DysfunctionalLikeExpectNeutralLive withDislike
LikeQAAAO
ExpectRQIIM
NeutralRIIIM
Live withRIIIM
DislikeRRRRQ

M = must-be, O = one-dimensional, A = attractive, I = indifferent, R = reverse, Q = questionable (a contradictory answer). Count the categories for each feature across respondents.

Worked Example: Features of a Cordless Tool

A product team surveys 40 users on four candidate features. The counts are illustrative.

FeatureMOAIRQCategory (most common)
A. Overheat shut-off2862301Must-be
B. Runtime per charge8245300Performance
C. Built-in work light2822800Attractive
D. Bluetooth app13102060Indifferent

To rank them, use the satisfaction coefficients: Better = (A + O) / (A + O + M + I) and Worse = −(O + M) / (A + O + M + I).

FeatureBetter (satisfaction if present)Worse (dissatisfaction if absent)
A. Overheat shut-off8 / 39 = 0.21−34 / 39 = −0.87
B. Runtime per charge29 / 40 = 0.73−32 / 40 = −0.80
C. Built-in work light30 / 40 = 0.75−10 / 40 = −0.25
D. Bluetooth app13 / 34 = 0.38−4 / 34 = −0.12
Attractive (delighters)Performance IndifferentMust-be (basic) A B C D Dissatisfaction if the feature is absent (0 to 1) Satisfaction if present (0 to 1) A overheat shut-off B runtime per charge C work light D Bluetooth app
The plot shows the magnitude of the dissatisfaction coefficient (0 to 1) on the horizontal axis and the satisfaction coefficient on the vertical axis.

Decisions. The overheat shut-off is non-negotiable: the product is unacceptable without it, but adding it wins little. Runtime is where competition happens, and improvement earns real satisfaction. The work light is cheap to add and delights, so it is a good differentiator. The Bluetooth app is expensive and most users do not care, and 6 of 40 dislike it, so it drops from the list, for now. The team also knows that today's delighter, the work light, may become expected, so it will re-run the survey in a year or two.

Analyze your own survey with the Kano Model Analyzer.

Self-Assessment Questions

  • Do we use more than one source for customer input?
  • Have we translated customer words into measurable requirements?
  • Do we know which features are basic expectations and which delight?
  • Did we ask both functional and dysfunctional questions, with enough respondents?
  • Do we repeat the survey as customer expectations change?

Common Mistakes

Asking Only What Customers Want

People rarely mention basic expectations or things they have never seen. Observe and ask the paired Kano questions.

Surveying the Wrong Customers

Use the customers you want to win, not only the ones who answer the phone.

Adding Every Feature Requested

Performance and delighter features cost money. Use the categories to decide what earns its place.

Treating Categories as Permanent

Yesterday's delighter is tomorrow's expectation. Refresh the study.

Voice of the Customer and the Kano Model: Frequently Asked Questions

What is the Kano model?

The Kano model, developed by Noriaki Kano in the 1980s, classifies product features by how they affect customer satisfaction. Must-be features are expected and cause dissatisfaction when absent, performance features raise satisfaction in proportion to how well they are delivered, and attractive features delight when present but are not missed when absent.

How do you run a Kano survey?

For each feature, ask how the customer would feel if the product had it (the functional question) and if it did not (the dysfunctional question), using the answers like, expect, neutral, live with, and dislike. Combine the pair using the Kano evaluation table, then count the categories across respondents to find the most common one.

What is a critical-to-quality (CTQ) characteristic?

A CTQ is a measurable product or process characteristic that reflects a customer requirement, with a target and tolerance. It is created by translating the customer's words into a specific, measurable requirement, for example turning "the battery should last a whole job" into runtime per charge of at least a stated number of minutes.

Sources and Further Reading

  • Noriaki Kano and colleagues, "Attractive quality and must-be quality," Journal of the Japanese Society for Quality Control, 1984.
  • Charles Berger and colleagues, "Kano's methods for understanding customer-defined quality," Center for Quality Management Journal, 1993.
  • Thomas Pyzdek and Paul Keller, The Six Sigma Handbook, on voice of the customer and CTQ.
  • ASQ Certified Six Sigma Black Belt Body of Knowledge, customer identification and requirements.