Six Sigma

SIX SIGMA AND OUR APPROACH

The term itself (six sigma) comes from manufacturing jargon and without going into specifics and technical talk you should just remember that it refers to a process that has only 3.4 defects in a million output units – be it physical products or other particular tasks that can be measured in units.

It is a rigorous and disciplined methodology that uses data and statistical analysis to measure and improve a company's operational performance by identifying and eliminating "defects" in manufacturing and service-related processes.We help organizations to implement Six Sigma by identifying the right projects, help them execute the project most cost effective way.

Choose the right Method for six Sigma implementation ?

Six sigma DMAIC method is to give continuous improve to the manufacturing process. Different method are providing different result. Therefore, understand the requirement or needed is important.

There are some other method such as DMADV, DFSS, DMADD, Lean six sigma and Ford 8D other than DMAIC but six sigma majority using DMAIC (Define, measure, analyze, improve and control) on the manufacturing process improvement. Below is the simple graph to show the different result from different method if use them in the right way.

DMAIC (Define, Measure, Analyze, Improve, Control):

This framework to drive business improvements that help an organization’s processes reach levels of performance never before seen.

  • Define – What is important? Define the project goals and customer deliverables (internal and external)
  • Measure – How are we doing? Measure the process to determine current performance
  • Analyze – What is wrong? Analyze and determine the root cause(s) of the defects
  • Improve – What needs to be done? Improve the process by permanently removing the defects
  • Control – How do we guarantee performance? Control the improved process’s performance to ensure sustainable results

DMADDD (Define, Measure, Analyze, Design, Digitize, Draw-down):

Part of Motorola’s Digitization effort, DMADDD is used to drive the cost out of a process by incorporating Digital improvements. These modifications can drive dramatic improvements in efficiency by identifying non-value tasks and using simple web-enabled tools to automate certain tasks. In doing so, employees can be freed up to work on more important duties.

  • Define: Where must we be leaner?
  • Measure: What’s our baseline?
  • Analyze: Where can we free capacity and improve yields?
  • Design: How should we implement?
  • Digitize: How do we execute?
  • Draw Down: How do we eliminate parallel paths?

DMADV (Define, Measure, Analyze, Design, Verify):

Also known as DFSS (Design for Six Sigma), this tool set is used when an organization needs a new product, process, or service. Using this tool set, Black Belts optimize performance before production begins.

  • Define: What’s important?
  • Measure: what is needed?
  • Analyze: How will we fulfill?
  • Design: How do we build it?
  • Verify: How do we know it will work?

Ford Global 8D:

This analytic tool set is used when an organization needs to bring performance back to a previous level. It addresses a “special cause.” Ford Global 8D is a problem-solving method used to close the gap

  • What Problem needs solving?
  • Who should help solve the problem?
  • How do we quantify symptoms?
  • How do we contain it? What’s the root cause?
  • What’s the permanent corrective action?
  • How do we implement ?
  • How can we prevent this in future? Who should we reward?

Six sigma tools

Six sigma manufacturing tools is to help organization move toward six sigma qualified process. To achieve six sigma qualify process, six sigma tools - measurement system analytics (MSA), T-test, sources of variation (SOV), statistical process control (SPC) and design of experiments (DOE) are playing important roles. Therefore, understand the function of each six sigma tools are very important.

  • Measurement System Analysis (MSA) is to evaluate the variation on the measurement system to ensure the quality data used for analysis. MSA is to reduce or avoid the variation occur due to the reproducibility (person, procedure, environment or work piece error) and repeatability (instrument and standard error).
  • T-Test is a six sigma comparative method. T-test show the confident interval of the process. T-test including one sample T-Test, two sample T-test and multi sample t-test. And all type of T-test can be either one side or two side T-test. T-test is the tools help on make decision by showing the confident interval which is sigma.
  • Sources of variation (SOV) is a six sigma tool that used to reduce the variability of key process characteristics or parameters (e.g. process outputs, responses). Reduce the variability directly reduce the cost and improve on the process.
  • Statistical process control (SPC) is a six sigma process stability controller and estimator. SPC used for monitoring the process, estimate the abnormality. It gives signal once found any possibility that the abnormality going to happen. So that, the preventive action can be carried out before the problem.
  • Design of experiments (DOE) is a six sigma tool that help in process optimization. Design of experiments also called as Taguchi experiments which is created by Dr.Taguchi.

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