Six Sigma

Six Sigma at many organizations simply means a measure of quality that strives for near perfection. Six Sigma is a disciplined, data-driven approach and methodology for eliminating defects The statistical representation of Six Sigma describes quantitatively how a process is performing. To achieve Six Sigma, a process must not produce more than 3.4 defects per million opportunities. A Six Sigma defect is defined as anything outside of customer specifications

Objective
The fundamental objective of the Six Sigma methodology is the implementation of a measurement-based strategy that focuses on process improvement and variation reduction through the application of Six Sigma improvement projects. This is accomplished through the use of two Six Sigma submethodologies: DMAIC and DMADV.

Performance Standards

2 3 4 5 6

PPM
308537 66807 6210 233 3.4

Yield
69.1% 93.3% 99.38% 99.977% 99.9997%

Current standard

World Class

Process performance

Defects per million

Long term yield

Financial Aspects Benefits of 6 approach w.r.t. financials

-level Defect rate Costs of poor quality Status of the (ppm) company 6 3.4 < 10% of turnover World class 5 233 10-15% of turnover 4 6210 15-20% of turnover Current standard 3 66807 20-30% of turnover 2 308537 30-40% of turnover Bankruptcy

The DMAIC Methodology

The DMAIC project methodology has five phases: Define the problem, the voice of the customer, and the project goals, specifically. Measure key aspects of the current process and collect relevant data. Analyze the data to investigate and verify cause-and-effect relationships. Determine what the relationships are, and attempt to ensure that all factors have been considered. Seek out root cause of the defect under investigation. Improve or optimize the current process based upon data analysis using techniques such as design of experiments, poka yoke or mistake proofing, and standard work to create a new, future state process. Set up pilot runs to establish process capability. Control the future state process to ensure that any deviations from target are corrected before they result in defects.

The DMADV Methodology

The DMADV project methodology, known as DFSS ("Design For Six Sigma"), features five phases: Define design goals that are consistent with customer demands and the enterprise strategy. Measure and identify CTQs (characteristics that are Critical To Quality), product capabilities, production process capability, and risks. Analyze to develop and design alternatives, create a high-level design and evaluate design capability to select the best design. Design details, optimize the design, and plan for design verification. This phase may require simulations. Verify the design, set up pilot runs, implement the production process and hand it over to the process owner(s).

Key personnel in successful Six Sigma programmes

Black Belts
Six Sigma practitioners who are employed by the company using the Six Sigma methodology work full time on the implementation of problem
solving & statistical techniques through projects selected on business needs become recognised Black Belts after embarking on Six Sigma training programme and completion of at least two projects which have a significant impact on the bottom-line

Black Belt requirements

Black Belt required resources
-Training in statistical methods. -Time to conduct the project! -Software to facilitate data analysis. -Permissions to make required changes!! -Coaching by a champion or external support.

Black Belt role!

In other words the Black Belt is

-Empowered. -In the sense that it was always meant! -As the theroists have been saying for years!

Champions or enablers
High-level managers who champion Six Sigma projects they have direct support from an executive management committee orchestrate the work of Six Sigma Black Belts provide Black Belts with the necessary backing at the executive level

Further down the line - after initial Six Sigma implementation package
Master Black Belts
Black Belts who have reached an acquired level of statistical and technical competence Provide expert advice to Black Belts

Green Belts
Provide assistance to Black Belts in Six Sigma projects Undergo only two weeks of statistical and problem solving training

Six Sigma instructors (ISRU)

Aim: Successfully integrate the Six Sigma methodology
into a companys existing culture and working practices

Key traits
Knowledge of statistical techniques Ability to manage projects and reach closure High level of analytical skills Ability to train, facilitate and lead teams to success, soft skills