Optimizing the DSSC fabrication process using Lean Six Sigma

Brian Fauss, Lakshmi V. Munukutla, Laura Main, Gerald Polesky, Arunachala Mada Kannan

Research output: Chapter in Book/Report/Conference proceedingConference contribution

1 Scopus citations


Dye sensitized solar cells (DSSCs) belong to an innovative third generation photovoltaic technology, which is demonstrating tremendous potential to become a revolutionary technology due to recent breakthroughs in fabrication cost. A seven-step quality improvement method is implemented to enhance process efficiency and effectiveness of the DSSCs. Lean Manufacturing's 5S method successfully increased efficiency in all of the processes. Six Sigma's DMAIC methodology is used to identify and eliminate each of the root causes of defects in the critical titanium dioxide deposition process. These optimizations resulted with the following significant improvements in the production process: 1. fabrication time of the DSSCs is reduced by 54%; 2. fabrication procedures improved to the extent eliminated all critical defects 3. The yield of good cells increased from 17% to 90%.

Original languageEnglish (US)
Title of host publicationOrganic and Hybrid Photovoltaic Materials and Devices
PublisherMaterials Research Society
Number of pages6
ISBN (Print)9781632661265
StatePublished - 2013
Event2013 MRS Spring Meeting - San Francisco, CA, United States
Duration: Apr 1 2013Apr 5 2013

Publication series

NameMaterials Research Society Symposium Proceedings


Other2013 MRS Spring Meeting
Country/TerritoryUnited States
CitySan Francisco, CA

ASJC Scopus subject areas

  • General Materials Science
  • Condensed Matter Physics
  • Mechanics of Materials
  • Mechanical Engineering


Dive into the research topics of 'Optimizing the DSSC fabrication process using Lean Six Sigma'. Together they form a unique fingerprint.

Cite this