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Not just a management fad, Six Sigma is a structured process and
set of tools focused on reducing variation and delivering near defect-free
products and services. The process can be used in a variety of
applications, including reducing costs in manufacturing processes, developing
new products (Design for Six Sigma), and business process improvement.
This approach focuses on the aspects of the product or business process that are
most critical to the customer. When applied using a systems approach and
in conjunction with Lean Manufacturing, there is a synergistic boost to your
profitability.
The five step approach used in Six Sigma:
Define
Select the appropriate customer-focused defect or problem. Document the
business impact and the project deliverables in the project charter.
Measure
Measure and document the current process (process mapping), identify key
response variables (cause and effect matrix, failure mode and effects analysis--FMEA),
and evaluate the measurement systems and tools (gage R&R). Use a
statistical approach to data analysis and measurements.
Analyze
Identify root causes of defects or sources of variation. Extensive use of
statistical analysis is employed (confidence intervals, hypotheses testing,
analysis of variance, etc.)
Improve
Eliminate the root cause of defects or reduce sources of variation using Design
of Experiments (DOE), response surface analysis, and evolutionary operations (EVOP).
Control
After improvements are implemented, institute controls and procedures to sustain
the improvements.
What is a Six Sigma Black Belt?
Motorola used the term “Black Belt” to describe “an individual who
has developed a synergistic proficiency between his or her technical discipline
and the Six
Sigma strategies, tactics, and tools.”
Six Sigma projects are typically led by black belts who are highly trained in
the DMAIC (Define, Measure, Analyze, Improve, Control, see above) process.
Savings from Black Belt projects vary depending on the type of project; typical
savings are in the range of $175,000 to $400,000 per project.
Our Six Sigma Black Belt associate has a PhD in Materials
Science and has held scientific and leadership positions at IBM, Honeywell
International, and Allied Signal. He has been a key driver using Six Sigma
to accelerate several new product development projects leading to multimillion
dollar revenues.
Summary
Six Sigma can be used to:
reduce manufacturing costs; thereby increasing profitability
accelerate new product development; adding new revenues and profits
and reduce defects; also increasing profitability
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