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Mike Stone
Agenda
Introduction to Six Sigma
Full Life-Cycle Case Study
Prepared by Mike
Stone
Introduction
Six Sigma was invented by Motorola, Inc. in
1986 as a metric for measuring defects and
improving quality. Since then, it has evolved to
a robust business improvement methodology
that focuses an organization on customer
requirements, process alignment, analytical
rigor and timely execution.
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http://www.motorola.com/content/0,,3074-5804,00.html
Stone
Prepared by Mike
Stone
Key Concepts
A process is all the activities involved in
producing a product or service for a customer. It
is cross-functional in nature
Quality is defined by customer requirements for
the chosen process
Defects are defined and counted
Inconsistencies in the process, known as
variation, are studied
Causes of variation are identified and addressed
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Key Terminology
Critical to
Quality
Defect
Opportunity
Process
Capability
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Key Terminology
Variation
Stable
Operations
Common Cause
of Variation
Special Cause
of Variation
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Stone
DMAIC
Define
Measure
Analyze
Improve
Control
Team Chartering
Customer Focus
Process Mapping
Measurement
Variation
Data Collection
Data Analysis
Process Analysis and Focus
Root Cause Analysis
Quantify Opportunity
Generate Solutions
Select Solutions
Implementation Planning
Monitor the Process
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Documentation
Stone
Institutionalize
Case Study
IT services business
Customer service call center
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Project Selection
Business strategy
How important is customer satisfaction?
How important is it to attract new customers?
Competitive position
How do we compare to our competitors?
Benchmarking
Best projects
Issue is well-defined with supporting data
Scope is well-defined
Objectives are stated in business terms and are
measurable
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Project Selection
Customer satisfaction
Average
Lower than best-in-class in industry
Define
Team Chartering
Goal statement: "Increase the call center's industrymeasured customer satisfaction rating from its
current-level (90th percentile = 75 percent) to the
target level (90th percentile = 85 percent) by end of
the fourth-quarter without increasing support costs.
Milestones, tasks, responsibilities, schedule and
communication plan.
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Define
Customer Focus
SIPOC diagram identify customers (stakeholders)
Customers
Staff
Business
Define
Requirement
Measure (CTQ)
Wait Time
Customer Satisfaction,
Support Cost
Days to Close
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Define
Process mapping
Helpful during the Measure phase, as the project
team considers how and where to gather data that will
shed light on the root cause of the issues most
pertinent to the project's goals.
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Measure
Define measures and how the data will be
gathered
Example:
Customer Satisfaction
By industry standard monthly survey
The project will require additional, more frequent, case-bycase customer-satisfaction data. A measurement system that
tracks with the industry survey will be devised and validated.
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Measure
Define performance standards
Example:
Customer Satisfaction
Current Baseline
90th Percentile / 70-80% Satisfied
Performance Target
90th Percentile / 85% Satisfied
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Measure
Identify segmentation factors for data
collection plan
Focus data collection effort
Use cause-and-effect tools
How is Y naturally segmented?
Call center, product type?
Measure
Assess measurement system
Accuracy
Does the measure agree with the truth?
Repeatability
Does the system always produce the same value?
Reproducibility
Will different people get the same results?
Stability
Is the system accurate over time?
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Measure
Collect the data
Automated
Manual
New metrics may be needed
Analyze
Measure process capability
Compare current performance to standards
Segment data
Slice and dice data to look for patterns to find
causes of variation
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Analyze
Identify possible Xs
Likely suspect causes of variation
Analyze
Refine the benefit forecast
Update the forecast of how much improvement can
be expected
Found that key support cost drivers (the delays and
interruptions during call-servicing) were the same as
those known to drive down customer satisfaction so
a win-win seemed to be possible.
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Improve
Identify Solution Alternatives
Driving Xs
Solution Alternatives
Staffing
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Improve
Verify the Relationships Between Xs and
Ys
Solution Selection Matrix
Solution Alternatives
Customer Requirements (CTQs)
Regression Analysis
Determine the strength of each solution against the
CTQs
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Improve
Select and Tune the Solution
Details of the plan for the Monday staffing pilot
program:
Xs to adjust: Staffing level (add five for pilot, full
increment to wait for evidence plan works)
Ys to measure for impact and unintended side effects:
Wait time, v/s ratio, customer satisfaction,
transfers, callbacks, service time.
Compare "new staff" versus "old staff" (hypothesis
test).
Measure monthly to observe learning curve effect,
if any
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Improve
Details of the plan for the Monday staffing pilot
program:
Measurement system issues: Revise existing
sampling plan and data collection process to
distinguish new staff from old staff.
Because the current customer satisfaction sampling
gives only 1 data point per month (not enough to see
a change), arrange a special sample five per day for
the first 60 days of the pilot (80 percent from existing
staff, 20 percent from new staff).
People and logistics issues: Communicate what is
happening and why. Emphasize evaluation is not of
individuals, only overall impact.
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Improve
Implement Solution
Pilot, if possible
Control
Develop Control Plan
Management control dashboards Ys
Operational control indicators Xs
Business Growth
Customer Satisfaction
Support Cost per Call
Days to Close
Wait Time
Transfers
Service Time
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Control
Implement Process Control
Ongoing data collection and presentation
Close Project
Roll out process changes
Training
Transition control to management
Validate results
Refinements
Project
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post mortem
Tools
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Tools
ANOVA
ANalysis Of VAriance (ANOVA), a calculation procedure
to allocate the amount of variation in a process and
determine if it is significant or is caused by random noise.
Tools
Control Chart
A graphical tool for monitoring changes that occur within
a process, by distinguishing variation that is inherent in
the process (common cause) from variation that yield a
change to the process (special cause).
Kano Analysis
Kano analysis is a quality measurement tool used to
prioritize customer requirements based on their impact to
customer satisfaction.
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Tools
Pareto
The Pareto principle states that 80% of the impact of the
problem will show up in 20% of the causes. A bar chart
that displays by frequency, in descending order, the most
important defects.
Run Chart
A performance measure of a process over a specified
period of time used to identify trends or patterns.
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Tools
X-Bar and R Charts
This set of two charts is the most commonly used
statistical process control procedure. Used to monitor
process behavior and outcome overtime.
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Resources
http://www.isixsigma.com/
http://www.sixsigmainstitute.com/
http://www.motorola.com/motorolauniversity
http://www.ge.com/sixsigma/
The Six Sigma Way: How GE, Motorola, and Other Top Companies
are Honing Their Performance by Peter S. Pande, Robert P.
Neuman, Roland R. Cavanagh
Fourth Generation Management by Brian L. Joiner
Leading Six Sigma by Ronald D. Snee and Roger W. Hoerl
The Pocket Idiots Guide to Six Sigma by Marsha Shapiro and
Anthony Weeks
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