What is Six Sigma?

In 1986, Motorola, Inc. created the term “Six Sigma”. It refers to a group of methods and instruments that are intended to improve the effectiveness and efficiency of business operations. 

It uses statistical methods to identify and eliminate defects. Six Sigma focuses on delivering high-quality products and services while minimizing error and waste. This technique creates a culture of ongoing process improvement. It encourages companies to provide customers with superior goods and services. 

Six Sigma creates a system for locating and fixing mistakes in business operations. It offers strategies to raise the standard of operations and efficiency.

Synonyms

• Process Improvement Methodology
• Quality Management System
• Operational Excellence Framework
• Lean Six Sigma
• Continuous Improvement Strategy

The 5 Steps of Six Sigma Methodology

The DMAIC and DMADV are the two main Six Sigma methods. These two methods fit different business needs so the method you choose will depend on your business. 

DMAIC focuses on enhancing current goods and services. The goal here is to increase consumer satisfaction. It's a data-driven technique that works well for many companies.

On the other hand, DMADV is a tool used to design or redesign various processes related to the production of goods or the provision of services. It is a part of the Design for Six Sigma (DFSS) process. When new methods need to be developed or when optimization fails to bring current processes up to speed with customer demands, DMADV is used.

Understanding these two methods is crucial for professionals looking to implement six sigma effectively. Here’s a breakdown of the two:

Steps For DMAIC

DMAIC is an acronym that describes the five steps you need to take. It is used when companies want to refine existing processes to eliminate defects. This data-driven approach works to enhance products and services to improve customer satisfaction. 

1. DEFINE

A customer-centric approach is the first step in the Six Sigma process.

Step 1: Define the business challenge from the customer’s perspective.

Step 2: Set specific goals. 

Step 3: Create a process map to ensure that you’re aligned with stakeholders. 

2. MEASURE

This phase is all about identifying key performance metrics and choosing tools to measure progress. 

Step 1: Quantify the issue with relevant data.

Step 2: Establish a performance benchmark. 

Step 3: Assess the proposed measuring system. And figure out if it assists you in reaching your goal.

3. ANALYZE 

In the third phase, you evaluate the process performance and identify factors affecting it.

Step 1: Assess the effectiveness and efficiency of your current process. 

Step 2: Put your objectives into numerical form. This could be a goal to increase efficiency by 10%.

Step 3: Analyze past data to identify process variations.

4. IMPROVE

This phase focuses on refining the process to enhance performance.

Step 1: Identify potential causes of defects.

Step 2: Determine how the variables relate to one another.

Step 3: Determine process tolerance. This is the acceptable limit for variations in a certain product. Use validation tools and optimization techniques to achieve process tolerance.

5. CONTROL

In this last stage, you ensure that the improvements are sustainable over the long term.

Step 1: Make sure the measuring system is reliable.

Step 2: Determine the capabilities of the process.

Step 3: Put the improved process into action.

Steps For DMADV

The goal of DMADV is to create a whole new solution. This can be a new operational process, product, or service. It is used when existing processes fail to meet customer demands, even after improvements. These are the five steps of DMADV:

Step 1: Clearly state the goal of the new process, product, or service.

Step 2: Assess critical elements and capabilities of the new solution.

Step 3: Examine the facts and create several design options before choosing the best one.

Step 4: Create and test the prototype of the option you chose.

Step 5: Use a pilot program and simulations to validate design efficiency.

Principles of Six Sigma 

Six Sigma operates on five core principles. These principles drive improvement and efficiency. They are:

1. Customer Orientation

The primary goal is to enhance customer satisfaction. To do this, you must first understand your customer’s needs. This allows you to set quality standards accordingly.

2. Evaluate the Value Chain 

Create a process to identify defects. Gather relevant data, set goals, and ensure everything you do contributes to improving operations.

3. Get Rid of Defects

After identifying defects, businesses must remove steps that do not add value. If traditional processes don’t reveal issues, you can try advanced technologies. These are more capable of pinpointing problem areas.

4. Involve Stakeholders

A successful Six Sigma procedure requires collaboration. Employees should be trained in Six Sigma methodologies. This ensures smooth project execution and minimizes the risk of failure.

5. Creating a Responsive and Adaptable System

Eliminating defects often requires employees to change work habits. Your company should foster an environment that supports process changes and encourages continuous improvement.