What is Six Sigma?

Six Sigma is a continuous improvement methodology that focuses on reducing the defects and process variations in a product or service. When an organization has a business process that can consistently produce a product / service that has zero defects and which is meeting customers’ requirements, it will result in an increase in customer satisfaction and loyalty which in turn will lead to higher revenues and profits for the organization.

An organization is said to have achieved six sigma standard when their process produces only 3.4 Defects per Million Opportunities (DPMO). This is equivalent to first pass yield of 99.99966% or in other words, the process only has 0.00034% defects. This is one of the ultimate goals of implementing Six Sigma.

Charts from Six Sigma training conducted by our consultants

How is Six Sigma practised?

Six Sigma is practised through using a highly systematic and analytical approach to solve a problem. This approach is known as DMAIC. Each letter in DMAIC stands for each phase of the problem-solving approach, which is Define, Measure, Analyze, Improve and Control. The intention of using this approach is to ensure we use data to objectively identify and solve the root cause of a problem so that it would not recur again. 

Let’s look at each problem-solving phase in detail as follows:

Define      : Define the requirements to satisfy the customer and solve the problem

Measure  : Determine the critical data to collect in order to resolve the problem

Analyze    : Investigate the root causes of the problem by analyzing the data collected

Improve   : Brainstorm ways to solve the root causes or prevent them from recurring

Control     : Develop ways to sustain the implementation of solutions

 An example of the DMAIC Project Roadmap done by one of our consultants

Implementation of Six Sigma Program?

Six Sigma is implemented through training the entire organization in Six Sigma philosophy and basic problem-solving tools. Subsequently, a project team is formed and led by different levels of six sigma practitioners to address the different tiers of organizational problems. The different levels of six sigma practitioners are identified by their “belts” – White, Yellow, Green, Black and Master Black. The darker the belt color, the higher is the proficiency of the practitioner in Six Sigma methodologies and tools. The diagram below illustrates the typical organizational structure of Six Sigma programs.

http://leaninstituteasia.comlean-six-sigma-training/What are the typical tools used in Six Sigma projects?

DEFINE                : Project Charter, Voice of Customer, Critical to Quality, SIPOC, Stakeholder Analysis, 5W1H.

MEASURE            : 3 Reals/Gs, Process Map, Data Collection plan, Tagging, Tally Sheet.

ANALYSE              : Pareto Diagram, Histogram, Run Chart, Scatter Plot, 5Whys, Review Process Map

IMPROVE             : Brainstorming, Mistake Proofing, FMEA, Simulation Software, Piloting, Design of Experiment

CONTROL            : Statistical Process Control Charts, Control Plan, Checklist, Documentation, Visual Management

What are the benefits of Six Sigma?

• Systematic approach to problem-solving prevents the recurrence of root causes
• Shifts organization to focus on solving root causes rather than treating symptoms
• Improved employee morale
• Reduce process cycle time and variation
• Reduce costs
• Improve quality of product and services
• Improved customer satisfaction
• Increase long term revenues and profits