Sigma Six

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Project Management | Sigma Six

Understanding Six Sigma

What is Six Sigma?

Six Sigma is a formalized methodology which some companies use to measure and delivery quality to their customers.

Σ Sigma, a letter in the Greek alphabet, is also a term which scientists use to describe variation or deviation from a norm.

Companies who participate in Six Sigma programs strive for a statistical goal of six standard deviations between the mean and the closest specification limit for whatever process is being measured.

This translates to a permissible defect or error rate of just 3.4 errors or defects of out of every 1 million "opportunities" to create that error or defect, or a success rate of 99.9997%.

How did Six Sigma originate?

A Motorola Corporation Quality and Reliability engineer by the name of Bill Smith is widely credited with devising the Six Sigma process. He had concluded a study which determined that actual Motorola product failure rates were much higher than had been predicted when the products were designed. The high failure rates translated into additional warranty repair costs for Motorola and decreased customer satisfaction.

Mr. Smith went to Motorola's CEO and convinced him that the company would benefit financially from a formalized methodology which analyzed and controlled quality and reliability processes. This process became what is known as Six Sigma.

Does Six Sigma work?

There are many large and small businesses who have implemented Six Sigma programs successfully. It is reported that the General Electric Corporation saved over $10 billion dollars in the first five years after implementing their Six Sigma program.

Of course, there is no guarantee that Six Sigma will "work" for any particular organization. You only get out of it what you put into it.

What is the Six Sigma process?

There are actually two processes that are used under slightly different circumstances.

If a company already has a product or process that is not performing up to Six Sigma standards then they will usually initiate a process called DMAIC which stands for Define, Measure, Analyze, Improve, and Control.

If the company has a new product or process which they have yet to put into production then they normally use the Six Sigma process called DMADV which stands for Define, Measure, Analyze, Design, Verify.

What is the difference between DMAIC and DMADV
DMAIC consists of five steps which are used to improve the quality of existing products or processes. The official Six Sigma documentation defines DMAIC as:

D Define customer needs and improvement goals M Measure variables of the process A Analyze data to establish inputs and outputs I Improve system elements to achieve performance goals C Control the key variables to sustain the gains

DMADV also consists of five steps which are employed before a new product or process is launched. The Six Sigma organization defines these steps as:

D Define the project goals and customer (internal and external) M Measure and determine customer needs and specifications A Analyze the process options to meet the customer needs D Design (detail) the process to meet the customer needs V Verify the design performance and ability to meet customer needs

Who can be a Six Sigma team member?

Each organization chooses their team members based upon the specific problem that is being addresses. Team members typically span a number of positions including executive and senior managers, department heads and line employees.

Strive for a statistical goal of six standard deviations between the mean and the closest specification limit for whatever process is being measured.

Each team member is defined by their level of Six Sigma training, experience and responsibilities. These levels are:

Champions:

These are members who are fully trained and qualified in the Six Sigma methodology.

Master Black Belts:

These are the people who are responsible for both teaching the Six Sigma methodologies to the Black Belts and acting as mentors to Black Belts and Sponsors.

Sponsors or Process Owners:

These are trained Six Sigma team members who work with the Black Belts to manage the defined processes for reducing defects.

Black Belts

Team leaders who have an ongoing and full-time responsibility for measuring, analyzing, improving and controlling the targeted processes.

Green Belts:

Team members who are responsible for applying specific Six Sigma methodologies to their specific jobs within the company. They have a similar skill level to Black Belts but administering Six Sigma is not their full time job.

How can I initiate a Six Sigma program in my company?

There are many consulting and training firms who will help you implement a Six Sigma program. You can use them to train your Black Belts and then take the remaining process over internally, or you can allow them to bring in teams who will remain on board until the program is implemented and functioning

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