Six Sigma

Six Sigma methodology provides the techniques and tools to improve the capability and reduce the defects in any process. Six Sigma is a fact-based, data-driven philosophy of quality improvement that values defect prevention over defect detection. It drives customer satisfaction and bottom-line results by reducing variation and waste, thereby promoting a competitive advantage. In simple terms, Six Sigma quality performance means no more than 3.4 defects per million opportunities. It was started in Motorola, in its manufacturing division, where millions of parts are made using the same process repeatedly. Eventually Six Sigma evolved and applied to other non manufacturing processes. Today you can apply Six Sigma to many fields such as Services, Medical and Insurance Procedures, Call Centers.

DMAIC
Six Sigma methodology improves any existing business process by constantly reviewing and re-tuning the process. To achieve this, Six Sigma uses a methodology known as DMAIC (Define opportunities, Measure performance, Analyze opportunity, Improve performance, Control performance).

DFSS or DMADV
Six Sigma methodology can also be used to create a brand new business process from ground up using DFSS (Design For Six Sigma) principles. Six Sigma Strives for perfection. It allows for only 3.4 defects per million opportunities for each product or service transaction. Six Sigma relies heavily on statistical techniques to reduce defects and measure quality. Six Sigma experts (Green Belts and Black Belts) evaluate a business process and determine ways to improve upon the existing process. Six Sigma experts can also design a brand new business process using DFSS (Design For Six Sigma) principles. Typically its easier to define

a new process with DFSS principles than refining an existing process to reduce the defects. Six Sigma incorporates the basic principles and techniques used in Business, Statistics, and Engineering. These three form the core elements of Six Sigma. Six Sigma improves the process performance, decreases variation and maintains consistent quality of the process output. This leads to defect reduction and improvement in profits, product quality and customer satisfaction.

Lean Six Sigma

Some Six Sigma practitioners have In recent years combined Six Sigma ideas with lean manufacturing to invent new a methodology. This new methodology is called Lean Six Sigma.

The three key elements of Six Sigma are:

1. Customer Satisfaction 2. Defining Processes and defining Metrics and Measures for Processes Using and understanding Data and Systems Setting Goals for Improvement

3. Team Building and Involving Employees Involving all employees is very important to Six Sigma. The company must involve all employees. Company must provide opportunities and incentives for employees to focus their talents and ability to satisfy customers. Defining Roles: This is important to six sigma. All team members should have a well defined role with measurable objectives.

Six Sigma in Business

Even though Six Sigma was initially implemented at Motorola to improve the manufacturing process, all types of businesses can profit from implementing Six Sigma..

Businesses in various industry segments such as Services industry (Example: Call Centers, Insurance, Financial/Investment Services), Ecommerce industry (Example: B2B/B2C websites), Education can definitely use Six Sigma principles to achieve higher quality. Many big businesses such as GE and Motorola have successfully implemented Six Sigma but the adaptation by smaller businesses has been very slow.

DMAIC 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. Implement control systems such as statistical process control, production boards , visual workplaces, and continuously monitor the process.

DMADV or DFSS The DMADV project methodology, also 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).