Six sigma

Contents

Conclusion
 What Is a Sigma?

A metric that indicates how well a

process is performing.
Measures the capability of the process to
perform defect-free work.
For discrete data it is calculated from
DPMO.
Sigma Level Defect Rate


2 308,537
3 66,807
4 6,210
5 233
6 3.4
 1,000,0
00
100,0
00

10,0
00 Averag
DEFECTS

e
1,00 Compa
0

10
0

1
0
Best-in-
Class
1
2 3 4 5 6 7

S
What is Six Sigma?
• It is a methodology for continuous improvement
• It is a methodology for creating products/ processes that perform
at high standards
• It is a way of knowing where you are and where you could be!
• It is a Quality Philosophy and a management technique

Note: Six Sigma is not:

• A standard
• A certification
Origin of Six Sigma

Motorola
the company that invented Six Sigma
• The term “Six Sigma” was coined by Bill Smith, an engineer with
Motorola

1987 - Motorola officially launched it’s Six Sigma program

 DMAIC
Six Sigma Improvement
Methodology
What is DMAIC ?

• A logical and structured approach to problem solving and process

improvement

• An iterative process (continuous improvement)

• A quality tool with focus on change management

E = Q x A
Effectivene Quality Acceptance
ss Improvement
The Approach

Practic
al

Statisti
cal

Statistic
al

Practic
al
Methodology

Identify and state the practical problem

Validate the practical problem by collecting data

Convert the practical problem to a statistical one,

define statistical goal and identify potential statistical
solution

Confirm and test the statistical solution

Convert the statistical solution to a practical solution

Define

Who wants the project/ Improvement and why ?

The scope of improvement

Key team members / resources for the project

Critical milestones and stakeholder review

Budget allocation
D
Measure

Ensure measurement system reliability

- Is tool used to measure the output variable flawed ?
- Do all operators interpret the tool reading in the
same way ?

Prepare data collection plan

- How many data points do you need to collect ?
-How many days do you need to collect data for ?
-What is the sampling strategy ?
-Who will collect data and how will data get stored ?

M
-What could the potential drivers of variation be ?

Collect data
Analyze

Understand statistical problem

Baseline current process capability

Define statistical improvement goal

A
Identify drivers of variation (significant factors)
Improve

Solution Design Developed And

Documented

Solutions Tested On A Small

Scale Or Pilot Program

I
Implementation Plan Developed And
Executed
Contro
l
ensures that the solution is working
effectively

Procedures Documented

Sustenance Plan
- Statistical Process Control
- Mistake Proofing
- Control Plan
C
Six Sigma Organization
 The Quality Team
Thought Leadership
Expert on Six Sigma
Master Black Belt Mentor Green and Black Belts

Backbone of Six Sigma Org

Mentor Green Belts
Full time resource
Black Belt Black Belt
Deployed to complex or “high
risk” projects

Part time or full time

Green Green Green Green resource
Belt Belt Belt Belt Deployed to less complex
projects in areas of functional
expertise
The Growth of Six Sigma

Mumbai
Dabbawala
CONCLUS
ION

Customer
Happy

Six sigma is about reducing variations in

a process
Thank
you