Pragmatic Six Sigma

These days there are many universities trying to sell you their Six Sigma training and certification package. But 6 Sigma training is much more than it used to be. Now with a variety of different six sigma packages to choose from and several different formats it can be more difficult than ever as a manager to make the choices that best meet the needs of both your employees and your company as well.

Essentially Six Sigma is nothing more than an integrated approach to a philosophy that has been proven over time as effective in improving business performance. It is based on making changes and improvements in the predictability of business processes to improve the overall results as well as create better business practices and improve the company's bottom line. And companies such as GE Capital for instance have saved boatloads of money simply by implementing the Six Sigma methodology into their company creaging higher profits and better overall results.

Six Sigma programs include those programs designed for specific project groups, those designed for an entry level understanding, as well as those that are designed for the differenet levels of management within the company. There are those training classes that are designed towards those with different roles in Six Sigma such as training classes for Black Belts, Green Belts, Yellow Belts, Master Black Belts, and of course Champions.

There are also a variety of training courses that are designed to apply 6 Sigma methodology in specific settings such as lean Six Sigma, Green Six Sigma, and Six Sigma for Health Care. There are also 6 sigma programs designed for project management as well. There are even condensed courses designed as introductory courses that can allow those who aren't well versed in Six Sigma to learn a little bit about what it entails before signing up their entire company for training and certification programs.

Six Sigma is perhaps as popular as it is because it means so many things to so many different companies. No matter what your company specializes in or how big or small it is there are ways to effectively use part or all of the Six Sigma method to improve your business, customer expereience, and your bottom line and from that perspective it is an incredible business management tool.

Categories: Six Sigma

Statistical thinking in Six Sigma practices is key to problem solving and achieving organizational objectives. It prevents the hassle of micromanaging every single process, and provides a blueprint for maximizing profitability. The philosophy depends on learning what problems are occurring and what causes them. This allows for the implementation of solutions that work.

In using statistical thinking, it is critical to recognize two fundamental points. The first is that every step, from start to finish, in delivering a product or service is connected to each other. Work occurs in a pre-defined system.

The second is that variations inside of this process exist. The variations can be good or bad. What they are, how often they occur, their cause, and how predictable they are determine what action can be taken to correct them.

Using statistical data is critical to this philosophy. It requires information that is reliable and unbiased based on the current environment. In essence, managers use statistical information to predict or solve statistical problems.

Before this can occur, it is necessary to ascertain what the current average production is. Once this is known, a target goal should be established. With these two points, it becomes possible to begin identifying and labeling variations that influence these numbers.

Variations are broken down into three different types: common, structural, and special. They may happen repetitively, occasionally, or originate from different places. Using statistical thinking, it becomes possible to see if any of these are common across all of the information collected.

• Common causes of variations in performance are normally predictable. These are things that are expected when everything is performing at its best. Correcting these variations often requires fundamental changes at the management level.
• Structural causes are variations that present as a result of equipment performance, or other structural component. These are unpredictable, and may look like a special cause at first glance.
• Special causes are random, unpredictable, and can stem from anywhere. They can be related to outside sources, or within the conversion process itself. These variations can be reduced or eliminated by changing the process at a higher level.

Once the causes are identified, there are different methods of applying changes within an organization. These steps must be laid out clearly, with foreseeable results. Using other statistical approaches, the path to achieving the target goal becomes clear. The Six Sigma attitude of statistical thinking results in improvements that are easily measured.

Categories: Six Sigma

In business administration we always come across the term strategic management, which specifies general objective to the business organization. It is this pursuit of a more defined general objective or direction for a business enterprise that became the foundation of the development of Six Sigma.

Six Sigma is sort of a strategic management tool in the area of business that deals with the key programs undertaken by general managers or the business owners themselves. Six Sigma consists of the use of the company's resources (or the factors of production) to enhance the performance of the business entity.

Six sigma aims to better the product quality by pinpointing and eventually eradicating the sources of errors or defects and reducing the inconsistencies or irregularities in production or manufacturing. Six Sigma also employs quality planning, quality control, quality assurance and quality improvement procedures for product quality enhancement. These four are the main components of the so-called quality management methods which are specifically defined within many business sectors.

Six Sigma additionally engages statistical methods such as data gathering and interpretation, surveys, and even experiments. Furthermore, Six Sigma invents a special set up of personnel within the business firm – the so-called "Black Belts", "Green Belts", and the like. These people are the experts in these means.

Incidentally, Six Sigma is a business management strategy originally developed by Motorola, USA in 1986, and became widely used in many areas of industry since 2010. Sigma projects undertaken in the firm adhere to a required procedure and answers to a calculated financial goals, namely profit growth and cost cuts. Six Sigma is mostly used in large business firms or organizations.

A milestone in the widespread of Six Sigma usage was General Electric's announcement of $350 million in savings (this was in 1998). This amount later surged to more than $1 billion, thanks to Six Sigma. Some industry consultants, the likes of Thomas Pyzdek and John Kullmann, believe that businesses with fewer than 500 employees are not likely to succed with Six Sigma implementation. They need to adapt the standard tactic to make it work for them. This is because both to the setup of Black Belts that Six Sigma entails and the fact that large business entities present more opening for the kinds of expansions Six Sigma is fit to result with.

Categories: Six Sigma

Many companies want some sort of guarantee that Six Sigma will work in their setting and while there are no guarantees it is easy to see why so many companies and CEO’s are drawn to this methodology. One that began working for Motorola back in the 1980’s, Six Sigma, is a process and program that has proved to be somewhat of a chameleon changing just enough to fit a variety of different companies and industries over the years.

It is not a new program but one that has been around and has stood the test of time. It doesn’t need to prove itself any further. It doesn’t need other companies to get onboard. Those companies who have tried it, trained for it, and implemented correctly have found that the results they are attaining have well exceeded any of their expectations. Most companies can simply not fathom the idea of being able to refine successes to the point of error that is so minute that it is beyond measurability.

When it comes to Six Sigma you will possibly hear from a few nay sayers that talk about lack of success and quantitative results of certain specific companies but always when the process is looked at it is not the 6 Sigma program and strategies that failed but the ways in which the company implemented the process. One of the most difficult aspects of Six Sigma comes during the implementation process and it is for this reason that each company needs to assign some team members to focusing directly on correct implementation.

There is no question that Six Sigma works. It is a proven system of statistical analysis that takes into account all aspects of running a business. It culminates everything and constantly assesses and reassesses results to help refine them to near perfect.

Every company wants perfection in whatever they are producing and most managers and business owners understand that attaining it will help to allow the business to function optimally, which will improve its bottom line. Most are not afraid of Six Sigma but are instead are afraid that they are not going to get the results that Fortune 500 companies are. There are reasons why top companies are just that and 6 Sigma implementation can help to boost just about any business to a success that until now has remained just outside of its reach. Every business can run leaner and more successfully and Six Sigma has come up with a plan to help every business become all that it can be.

Categories: Six Sigma

A six sigma business strategy is one in which a minimal amount of errors can be found. This is the high standard that should always be sought by businesses that want to make their customers happy. This must be the end goal. Nothing drives people away as fast as their finding defects in the different products that they have purchased. This shows that the company does not care about quality. This in turn gives those who have made the purchases no reason to come back to that company in the future. Why would they want to spend their time and money on a company that does not care about them?

One of the most important things that can be done to guarantee that the six sigma level of quality is always upheld is to make sure that all hypothesis testing is done before anything is put into practice. A hypothesis is basically just an educated guess. It is a guess that is based on all of the facts that have been gathered, but that still does not mean that it can be treated as a fact. This is the mistake that a lot of people make. They want to treat it as a fact instead, and they end up using the hypothesis in their business without find the holes in it.

If you do this, those holes will still come to light. A hypothesis is rarely perfect as soon as it is formulated. Testing needs to be done and the results need to be analyzed. Then the testing needs to be done again. This is the only way to know that something is really without fault, that it really can be inserted into the general business practices. There is no excuse for cutting corners and neglecting this.

The best hypothesis testing is done by many different people. It will have a number of different layers. This makes sure that something does not just work out as a fluke in one test even though it is a problem. This also makes sure that new eyes are always looking at the idea. The people who are seeing it are seeing it for the first time, even if it has been tested many times before. This gives them the very best chance to catch any of the mistakes that might remain.

Categories: Six Sigma

While Six Sigma has been shown to be an effective process for a wide variety of business types and industries, implementation can sometimes be a difficult task for leadership. Motivating team members to change some of the ways they have been completing tasks and doing their jobs can sometimes be stressful and challenging because of the comfort levels employees may have built up. Some Six Sigma and Lean tasks can seem difficult to employees initially and improvement implementations can be daunting to the untrained.

Team Motivation Tips

When beginning Six Sigma and Lean application within a business, one method of preventing employees from feeling overwhelmed and out of control can be to gain their insight and ideas. Making employees feel like they are part of the Six Sigma and Lean teams and ideals can help them grasp some of the ideas without feeling as though changes are over taking their comfort zones. In addition to making employees feel more comfortable with upcoming changes, taking time to gain employee ideas, regardless or roles, can be beneficial to the company as a whole and may result in positive changes.

Another method that businesses can use to make employees feel more comfortable with the application of Lean and Six Sigma is motivational speaking by professionals and authorities on the subjects. Hearing someone outside of the company discuss there various changes and principles can make ideas seem more concrete and less threatening.

Roles & Titles

Giving employees within a business defined roles within the implementation of Six Sigma and Lean can help provoke focus and give leaders a way to measure the different actions and improvements as well as some of the struggles employees may endure. Initial goals established should be achievable and not too far from reach without being so simple they do not provide a challenge for employees. Unrealistic goals can be daunting and overwhelming for employees, especially when a new task or set of principles like Lean or Six Sigma are applied to a business.

Highlighting Positive and Negative Results

As progress, improvements and downfalls are measured, calling employees together to look over results can be a great source of motivation and bring various tasks and teams together so the entire picture of what is being done, or not done, can be easily viewed. As waste is reduced or customer complaints decrease, showing employees the various positive affects that Six Sigma and Lean principles have provoked can be a motivational tool for pushing employees to continue on their paths and embrace their new roles and goals. Establishing team goals while getting together with individual employees to record goals can help provide unity while highlighting individual responsibilities as well.

Categories: Six Sigma

The name Six Sigma refers to a strategy of business management that Motorola developed starting in 1970 and spanning into 1986. The term Six Sigma is derived from manufacturing terms as used in the statistical modeling of a manufacturer’s processes. In manufacturing, a sigma rating is used to indicate the percentage of flawless products a process yields; a six sigma process will have fewer than 3.4 imperfect products per million.

The procedures that Motorola had implemented to increase their quality and lower their overall production costs were compiled by a Motorola executive, named Bill Smith, into a program called Six Sigma. The preceding six decades had seen considerable advancement in quality control programs such as Zero Defects, which was instituted by aircraft manufacturer Martin Marietta when they were building the Titan Missiles; these advancements contributed to the implementation of the Six Sigma strategy.

Motorola established a “six sigma” goal for all of their manufacturing processes, and the Six Sigma strategy was born.

The philosophy behind Six Sigma was that increasing the end quality of a product would result in greater efficiency and an improved bottom line. Previously, it was thought that increasing the quality of a product would increase the cost of it. However, Six Sigma proved that it was not quality that drove up the price of goods, but the lack of quality that generated returns, defects and repairs and therefore cost more in the long run. By the advent of the 21st century, almost three-fourths of the Fortune 500 companies had instituted the Six Sigma philosophy.

Although originally designed to increase manufacturing efficiency by increasing quality, the premise behind Six Sigma has been applied to many other business formats as well. Six Sigma now uses statistical analysis to identify areas wherein a company has wasteful procedures or processes and lacks consistency in their output. This identifies areas to be streamlined, upgraded and improved so that the overall efficiency and therefore the profitability of a company are maximized.

Recently, an innovative concept of combining Six Sigma strategies with those of lean manufacturing has given rise to a Lean Six Sigma concept of management. Motorola attributes the Six Sigma program with saving them more than $17 billion by 2006.

Categories: Six Sigma

Six sigma master black belts have been described as the people in upper management who coach employees on the practices of six sigma. Their purpose is to reduce the inefficiencies that plague businesses through complex statistical analyses. They also have the duty of ensuring that the new, more effective ways of doing business are the practices that continue to be implemented long term. Master black belts are highly versatile, as they have been trained in several different business strategies and can, therefore, help several different types of businesses to become six sigma companies.

One type of company that benefits greatly from a master black belt is the company that has not had any new innovations in a long period of time. A master black belt that has been certified in six sigma, can easily move from one department to another and implement changes. The reason they can do this so well is because their training has included the identification of any and all problems that keep the company from moving forward. Another big part of their training is to identify how the company can face those problems and improve upon them.

Within the company, a master black belt is the one that trains everyone on six sigma principles. Specifically, they will be the mentors for those directly below them, the black belts, and they also train the green belts that are just below the black belts. Their role is so extensive in this area that they actually write training manuals for everyone as well as perform their in-depth statistical analyses of the company’s current practices. Their duties continue as the six sigma projects are completed and the master black belts ensure that new practices are followed within the company.

In order to become a master black belt, managers have to become a certified black belt first. Not everyone is recommended to continue into the master black belt certification program. Those who would be good candidates to become a master black belt are those who have the greatest grasp on the concept of statistics. Statistics are highly important in six sigma, because master black belts are the ones who will perform statistical analyses of a company’s present practices in order to identify where the problems reside. They also need to be masters at interpreting the statistical data as well as following through with the changes that the data suggest need to be made. These qualities set them apart from the black belts.

Categories: Six Sigma

Six Sigma Yellow Belt certification is the most basic level of certification available. It provides a general knowledge of Six Sigma techniques, metrics, and methodologies. While most traditional jobs and companies don’t require that Yellow Belts possess knowledge about Lean, many courses now include this in their training.

A Yellow Belt is a core team member with a solid but general competency in Six Sigma practices. While a Yellow Belt may be responsible for running smaller process projects and handling other specific and significant tasks, they are not team leaders. Yellow Belts provide the support for Green Belt and Black Belt Six Sigma certified team members and leaders by gathering data. Yellow Belts identify the problems and feed their findings to the Green Belts and Black Belts.

Certification can be found online through a number of programs. They are structured to be self-paced for the busy professional. Six Sigma Yellow Belt training can be done at any pace, and within reasonable time limits. The course is usually completed between fifteen and thirty hours, with programs allowing access from three months up to a year.

Six Sigma Yellow Belt certification students will learn to communicate using Six Sigma concepts, and be able to relate those concepts to overall business objectives. They will understand their role in a Sigma Six deployment and become familiar with the DMAIC (Define, Measure, Analyze, Improve, Control) model, learning how to utilize each step of the methodology to improve processes. By the end of the course, Six Sigma Yellow belts will have an improved grasp of day-to-day workplace activities and how to identify and improve practices to raise the overall quality of work. They will be able to successfully participate in Six Sigma projects.

Six Sigma Yellow Belt certification is the most affordable choice for business people who wish to learn about Six Sigma and improve their own performance. Many programs offer a course including Lean concepts alongside one that does not. Everyday professionals will do fine obtaining their Six Sigma Yellow Belt certification without learning about Lean, but those serious about Six Sigma should take the integrated training. Prices range from $250 to $500, and include a comprehensive training program and official certification.

Categories: Six Sigma

There are many different management techniques being taught to eager managers and business owners’ alike but in the world of business one thing remains a fact and that is that Six Sigma has a greater potential to help your business then any other management technique of its kind. Of course there are a number of significant factors that make Six Sigma stand out above the rest but the following are some of the primary differences that have attracted business owners to this program.

One of the biggest things that make 6 Sigma stand out from the rest is the way in which it helps to integrate companies into a team where everyone is striving for the same goals. Managers love this because it creates unification at all levels and helps to not only produce better results but makes a group easier to manage. These principles give managers better control over both projects and results.

Another facet of Six Sigma that makes it so attractive to larger companies is the way in which results are calculated based on financial marks instead of by other criteria. Having the ability to measure results and prove them profitable is the most relevant way to ensure that projects and changes are benefiting the company as a whole. So many programs only measure results based on productivity and this can lead to inferences but with Six Sigma the numbers don’t lie and this helps when dealing with investors as well.

6 Sigma also puts the focus on the customer experience and on making the changes that need to be made to improve how the customer perceives your business. It is obvious that improving customer experience will help to improve your business since they are those who support your business and help bring it to success.

Overall, any companies that have already tried Six Sigma don’t need to be sold on it because they have seen first hand the ways in which it improves a business but for those debating which program to implement there are significant things that this management system brings to the table that others don’t. For this reason any company looking for a sure fire way to improve profitability should definitely consider this methodology.

Categories: Six Sigma

Getting your employees trained in Six Sigma can definitely be a challenge especially in a larger business and you may be wondering how it is that you will succeed in accomplishing such a task. Quite honestly, however, Six Sigma training is a very flexible program that can be done in the classroom or even online. This is of great assistance to companies who have a great number of employees to take through the process.

When looking to train your entire staff, begin first by getting those in upper management trained first. Since they will be your Six Sigma leaders they will need the best possible training and it is usually advisable to send these people to a class on Six Sigma. The classroom provides them with the opportunity to fully explore their questions and to get solid answers they can work with. And an additional benefit of the classroom setting is that it allows for them to hear questions that are posed by others in the class.

As your upper rung of the Six Sigma implementation you want to make sure that they have a keen understanding of the principles and the implementing of such principles throughout the structure of your business. The classroom setting will help them to explore the answers to the many questions they may have as Six Sigma Master Black Belts and Black Belts.

Those who fall lower on the Six Sigma tiers may be just as effectively trained through an interactive online program, preferably sponsored by the same group and the upper management employees are being trained by. Using the same training program will help ensure continuity and while your lower level employees train online they can always refer back to the more senior employees in the company for any questions they have or any guidance that they need as they work through the training program.

Six Sigma training can take a little time and may delay implementation but once you have employees who are well trained in the principles of Six Sigma you will find that you are ready to move full steam ahead. The better trained your staff is the better your initial results will be.

Categories: Questions and Answers, Six Sigma

One of the biggest keys to Six Sigma is the implementation and facilitation of the process and strategies and the great news is that it is your employees that will help to make this process successful throughout your business. The following are some of the main Six Sigma roles that you will need to fill in your company to make implementation as successful as possible.

EXECUTIVE LEADERS – Those members of your top management are those who are responsible for outlining the Six Sigma plan and guidelines for implementation. They will help to put in place the leaders on all levels of the company.

CHAMPIONS – Selection of these individuals is done by the Executive Leaders. These individuals are usually high ranking in the company and are responsible for putting the Executive Leaders’ vision into action. They are responsible for training those beneath them as well.

MASTER BLACK BELTS – These individuals lead those beneath them in the Six Sigma principles throughout the business process. They serve as coordinator between those in upper management and those directly beneath them.

BLACK BELTS – The Black Belts lead those beneath them and are completely trained by the Master Black Belts. This group of individuals helps to execute the plans passed down to them and make sure that Six Sigma implementation goes off without a hitch. They essentially are responsible for the running of Six Sigma at the lower levels of the business.

GREEN AND YELLOW BELTS – These are the lowest tiers of the business and are essentially the work force that works to make the changes that have been passed down. Even the lower level employees need to be trained and the 6 Sigma Black Belts see to it that they fully understand their role and the Six Sigma principles. These are the people who will put Six Sigma into action and are a very critical part of the process.

Six Sigma is something that works throughout your business and helps to unite employees towards a common goal which is ultimately a more successful business. Training on all levels is essential to Six Sigma implementation.

Categories: Questions and Answers, Six Sigma

If you have decided to use Six Sigma to help you bring your company to a level of perfection then you are definitely on the right track. Using this type of strategy will help to improve your profits and improve your customer satisfaction but when it comes to 6 Sigma you are not only training employees you are building a team and that is one way that Six Sigma really ties things together for your business. In order to get everyone involved Six Sigma works in levels which are known as belts and these belts help to get everyone involved in Six Sigma throughout the different areas of your business.

The three primary levels of Six Sigma are the Green, Black, and Master Black Belts although some Six Sigma Programs add a few other level to ensure that all employees are included equally in the implementation process. Each level has its own training and certification program.

GREEN BELTS – This is usually the initial level for most people in training and a Green Belt Certification can usually be accomplished within about 2 weeks of training. These employees will work under Black Belts and will be assisted by them in applying the principles they have learned.

BLACK BELTS – These employees usually undergo a more extensive four week program which includes everything that Green Belts have learned plus includes a more detailed understanding of the statistical end of 6 Sigma as well. This is a more advanced level of Six Sigma and so more training is required to obtain a Black Belt Certification.

MASTER BLACK BELTS – These are the most highly trained individuals in the Six Sigma structure and they of course learn everything that is included in the Green Belt and Black Belt training and more. These are the individuals in charge of the projects for the entire company. MBB training is much more complex and difficult and it is therefore designated for only the top people in the organization. Being a Master Black Belt is responsible for proper employee placement and overseeing problems and solutions this is an area of Six Sigma must be assigned to the most well trained and competent employees available. Having the right Master Black Belts in place can truly make or break your Six Sigma implementation.

Categories: Questions and Answers, Six Sigma

There are many companies implementing Six Sigma strategies into their business structure and one of the primary reasons for this is very simple. These strategies have been proven to work over and over again for some of the biggest companies in the world and as a result many other companies are hopping on the band wagon.

Some companies will inevitably try to take the easy and inexpensive way out and will try to implement Six Sigma strategies simply by reading a few books. While books on Six Sigma can be very helpful to learn more about the concepts that are involved they are in no way meant to be a replacement for Six Sigma training. The training is an invaluable part of learning all the principles as well as learning how to put them into practical application.

This business initiative is something that is very beneficial for companies because it addresses three main target areas which are improving customer satisfaction, reducing cycle time and reducing deficits. These three areas are the key to Six Sigma success.

Even after the training process is over their will be coaches put in place to help your business achieve Six Sigma success and will help to train black belts as well as all other employees about their role in implementing this process on their level of the business. This is one of the things that you will get from the training that you can’t get from books but of course there are many benefits that you receive from actually doing the training like having the opportunities to pose questions and ask for clarification. These can be very valuable when learning about Six Sigma.

So read your books and do your homework but if you want to really learn Six Sigma and implement it correctly within your business then you need to make sure that you get every employee the training they need. There is no replacement for a Six Sigma training course.

Categories: Certifications, Six Sigma

Of course it was a Motorola employee who came up with the Six Sigma strategies and made it what it is today. Motorola was looking for a better way to run their company and when looking at several different strategies that were already in existence, their employee saw something that made him think about things and put them together a little different to improve the overall results like no concept had ever done before. And this concept helped to earn Motorola several awards.

But you may be wondering what other companies are currently using Six Sigma principles in their business and the answer is probably most the biggest ones in the industries that currently exist. Big companies want big results and if you are looking to develop Six Sigma strategies in your current business structure than it is important to take a look at the success that some of the biggest companies in the world are getting with Six Sigma. Here are just a few of the biggest:

And honestly this is just a brief list of even the larger companies that are using Six Sigma business strategies for success and there are many smaller companies that have also begun to adapt Six Sigma principles into their businesses as well. With successful companies like these endorsing and using Six Sigma in their business infrastructure, it only makes sense for other businesses to follow those that are successful in their business structure and at the top of their field.

Categories: Business, Six Sigma

One of the key principles to the Six Sigma structure is the different levels that are used to keep everything running smoothly. The benefit of this type of program is that it involves people at all levels of company operations to create more synchronicity in meeting company goals. From top executives to the front line customer service representative every employee has their place in this tiered structure allowing for a more unified employee structure.

Executive Leadership – These employees are usually at the top of the food chain. They are the executives and aid in the overall company vision as well as the implementation of the Six Sigma methods that the company is using.

Champions – These are usually members of upper management. They tend to manage the day to day implementation of Six Sigma throughout the company and they assign Master Black Belts who are more hands on in the process.

Master Black Belts – Are the coaches of the Six Sigma group and they spend their days teaching and mentoring others on Six Sigma methods. This level is the overseer of the lower rungs.

Black Belts – Black Belts are usually those who hold middle management positions.

They help to execute Six Sigma company wide and help to bridge communication between the Master Black Belts and the Green Belts.

Green Belts – Are usually the employees who are working at the customer service level. These employees aid the Black Belts in specific projects in addition to their regular job responsibilities. They help to implement the Six Sigma program into daily operations.

Some companies use a slightly different tier system. Smaller companies tend to not use as many different tiers and many in the manufacturing sect use a middle role known as Expert between the Master Black Belts and regular Black Belts to improve the end result of products to the customer.

Six Sigma is an effective way to manage your business no matter what your specialty or staff size. Six Sigma principles can work to improve your bottom line and help management to track the results of their efforts. There are many different ways to get employees trained through online resources and seminars that will allow all your staff to become involved in making the company a better one and improving the bottom line which really does impact every employee in the company.

Categories: Six Sigma

The Purpose of using a Six Sigma method is to increase overall production without defects and to increase satisfaction without making any sacrifice. In general, Six Sigma is a way of making life easier for everyone involved. In any business using the Six Sigma methods, five steps will take that business from level one to level six. These steps involve the most logical and simple deployment of improvement of business processes and for initiating a business into the Six Sigma way.

Step One: Define Problems and Goals

After determining the improvement needed and the project has been selected, the first step is to define the barriers and the goals of said project. The ability to determine the specific problem that needs improvement is necessary to create the specific goal of what Six Sigma will do for that project. For example, what problems are identified? How long has the problem been going on and how big has it gotten? Can the improvements take place in a single project or will the problem need smaller projects?

Determine what the mission of the project will be by using the same terms the problem does. By doing so, the project has a better likelihood of succeeding. Finding a team of employees who can effectively manage not only the project, but the problem itself will serve to expedite the process in a logical and knowledgeable way.

Step Two: Analyze

The ability to analyze the situation and measure the enormity of the problem will be more effective in providing a solution that eventually encompasses the final goal. This is when the mapping of the project will take place. Mapping allows the confirmation of the project and the mission of the improvement in addition to uncovering any changes in the plan or goal that must take place before the initial phases of the improvement can happen.

Step Three: Theorize

This step involves the theorization of any and all possible causes for the initial problem that caused the need for the improvement project. To formulate a theory allows the project managers and others working on the solution to postulate, test and document all theories of what caused the problem. This effectively allows the improvement team to formulate a better plan for eliminating the problem.

Step Four: Planning and Improvement

This step allows the improvement project team to analyze all processes and possibly come up with improvements to them. For example, can a specific part of the project be completed in a more efficient way? Determining if any alternatives exist to make the project move along more efficiently is one of the most important steps and helps with overall implementation of the project and solution. Once the most effective plan has been determined, the project goes forward and the expected gains are achieved.

Step Five: Maintenance

This step allows the improvement teams to ensure that the gains they make during the entire process are continuing to be met. Once a solution is initiated, controlling it so the problem does not recur is important. Continuing audits of any processes while continuing to improve on the process is ideal.

Using these five steps are the way to Six Sigma achievements in product and quality control. Determining a problem and effectively coming up with a logical way to fix the problem is a lengthy and thought provoking process, but it is a process that has saved thousands of companies billions of dollars over the years, and will continue to do so in the years to come.

Categories: Methodologies, Six Sigma

When a person steps into a company that deploys the Six Sigma methodologies, it shows. From the moment that employee steps his foot in the door, he can tell the company in question is a worthy one, which has the ability to make their product better than the next one can. This employee also knows that by walking into a business that deploys Six Sigma, he will also become part of that team and become an active part of that Six Sigma Process. So, what does it mean to become part of Six Sigma and what will a Six Sigma candidate learn?

Yellow Belt

The Yellow Belt of Six Sigma is a level in which many who achieve it will go on to become Green and Black Belts in the future. The training process is very different for all involved and can be implemented online or by using formal learning methods. The specific method used depends on various factors such as if the person training is doing so on his own time or if he is doing so through a company who employs the Six Sigma method.

The process, no matter which method is used, will instill some basic knowledge in the trainee. This knowledge includes many of the basic technologies used for the improvement of production, reduction of process times and waste and the improvement in client satisfaction overall. Learning basic problem solving and gaining the ability to recognize and control the processes from which loss and waste results is only the beginning of the Yellow Belt training for Six Sigma. Learning the fundamentals of the methodologies then applying them come next. While the trainee works on mapping projects and taking on other small roles, he will study and learn enough to eventually achieve the yellow Belt Certification and go on to Green belt Studies.

Green Belt

The person who achieves the Green Belt is one who is functional in the Six Sigma methods and employs their knowledge of organization to the best of their abilities. Not only will the Green belt actively train using the ix Sigma methods for improving the business management and production process, but he will have a part in its active implementation within the organization. Ideally, this person will actively lead a quality control and improvement team within the organization and utilize hands on training. Because they are tasked with overall process and product improvement, the Green belt must prove his extensive and intimate knowledge of the processes.

Black Belt

Learning and becoming responsible for the process of implementation of projects involving the improvement of a business or a product is the main goal of the Black belt. Not only will he successfully implement DMAIC and DFSS projects, but he will also be adequately skilled in the implementation of all the tools involved with the Six Sigma processes and projects. Formal training combined with hands on training serve to educate the Black belt-to-be and when he has completed this training, he will complete an examination in which he must prove he is knowledgeable in the Six Sigma methodologies and implementation.

Whether a Black, Green or Yellow belt, all will receive more than sufficient training and education from higher leveled Belts, such as those whom have already achieved a Master’s Black Belt in addition to formal classroom training and/or online education. Additionally, in each stage of the process, the initiate into Six Sigma will pass an examination to show he has successfully learned and implemented all he knows to make Six Sigma a part of his life and management/employment processes on a day-to-day basis.

Categories: Certifications, Six Sigma

I'm often asked "What exactly IS Six Sigma, anyway?" In this post I shall attempt to give a beif overview tha answers this question.

Simply put, the Six Sigma (6 Sigma) method is a management strategy aimed towards business and the art of lessening the production failure rates. Designed initially to improve practices in which manufacturing defects would be effectively eliminated, Six Sigma eventually evolved into an entirely different business plan.

Origins

The original curve concept, from which the Six Sigma concept originated, evolved over centuries of work and is traced all the way back to the late 1700’s when Carl Frederick Gauss who was a mathematician from Germany and publisher of “Theoria Motus Corporum Arithmeticae” in which he introduced the normal “bell curve.” However, it was not until the 1920’s that the concept was applied to business and manufacturing, when Walter Shewhart was able to use Six Sigma as a product measurement standard.

While the Sig Sigma has been used for decades, the use of the term Sig Sigma did not come into play until an engineer from Motorola named bill Smith used it and Motorola has since trademarked the name. Additionally, the methods used in Six Sigma today came from Mr. Smith in 1988 when he authored a set of standards of which many quality control and improvement standards inspired.

Since Motorola’s Chairman Bob Galvin decided to use the DPMO, or Defects Per Million Opportunities method of measurement, Motorola has realized gains of over $16 billion, which is what set the stage for Six Sigma deployment everywhere, including many Fortune 500 companies.

Process

The Improvement of business overall is another part of Six Sigma and part of the overall evolution. The method gives business leaders the ability to improve their management and leadership skills overall while retaining the ability to manage and produce quality controlled product. The ability to understand what a client wants as opposed to what he needs is one aspect that is difficult to gauge in any business. Utilizing the Six Sigma concept allows management to fully understand and analyze what clients need and then tailor their business to produce products that meet those specifications by keeping defects to a minimum utilizing the Six Sigma processes of data and statistical analysis while minimizing variations and improving the overall sustainability and productivity of the business as a whole.

New Ventures

As a direct quality control system, Six Sigma has paved the way for new opportunities and better product overall for many businesses. As a matter of fact, Six Sigma’s extraordinary methods of analyzing statistical data and using it to keep defect products lower than ever has forged a new certification program in which people form all walks of life can become certified in the Six Sigma ways.

The process of becoming Six Sigma certified involves not only textbook study time, but also involves the student passing a written and sometimes and oral exam, depending on the who implements the training. Additionally, hands on training may be involved, since to show that the student is competent in a business environment requires adherence to rigorous standards. After passing the examinations, the student must also complete various Six Sigma practice projects in which he must show his skills and ability to use the method taught to him in a real world scenario. While no standardized training is available according to specific guidelines and regulations, Six Sigma courses are generally the same wherever they are given.

Defect Levels

The Six Sigma methodology typically allows a process to operate at above standard efficiency concerning output to defect ratio. For example, any manufacturer who employs the Six Sigma strategy typically has a defect aspect of one million products to 3.4 defects. Called a DPMO (defects per million opportunities), this means that the methodology should produce even less defects than this base standard.

The Motorola University on Six Sigma online defines their process as a metric, methodology and a total management system. Started solely as a way to reduce defects per million pieces of product manufactured, it has evolved into a total management process along the way. Defect reduction during the manufacturing process has paved the way for the method to be used in other parts of an organization as well.

Deployment

The Six Sigma methodology began as a simple principle then evolved into an entire culture from which any organization or business can effectively reduce their defective product and processes, one level at a time and realize overall gains. While it may take some time to implement a complete Six Sigma strategy and the business may run into some deployment problems along the way, that company can still realize gains by deploying the Six Sigma process one Sigma level at a time.

Sigma Level One recognizes the initial deployment of the entire Sigma process. This level allows up to 690,000 defects per million opportunities. Sigma Level Two allows up to 308,537 defects per million opportunities. Sigma Level Three recognizes up to 66,807 defects per million and so on. As the Sigma level becomes higher and more tightly controlled, the quality level becomes higher in relation to that control. This lowers the overall defects per million opportunities as the levels increase until the Six Sigma level is reached completely.

Overall, using the Six Sigma quality control doctrine within a company as a while is a lengthy, but achievable process. However, keep in mind that every person within that company must be on board to meet a complete Sig Sigma level of quality control and customer satisfaction.

Categories: Questions and Answers, Six Sigma