Part II: Overview of Six Sigma

Six Sigma
6 - A process quality measure indicating that there are 6 standard deviations between the process average and each (lower & upper) specification limit. The greater the number of s the smaller is the variation.

Process Improvement: DMAIC

Stands for Define, Measure, Analyze, Improve and Control DMAIC is a methodology within the Six Sigma system to improve existing processes.

DEFINE Understand and quantify the problem Discover the scope of work Formulate objectives Identify resources Build the action plan Identify roles and responsibilities Understand current process and operations Establish project charter, build team

MEASURE What to measure Plan for measurement Build operational definitions for data Understand data types Design data gathering tools Gather data and validate Prepare analysis tools

ANALYSIS Analyze data Verify and validate hypotheses Identify variation Determine vital few root causes Validate root causes Quantify improvement opportunity

IMPROVE Brainstorm solutions Develop the To-Be model Formulate action plans Identify potential risks Analyze cost and benefit Test the new process Plan for implementation

CONTROL Implement the solution Establish control plan Build the dashboards Monitor performance Maintain performance Close and handover Improve continuously

Process Design: DFSS

Stands for Design For Six Sigma Used for development of a new process, product or service (IDOV).
IDENTIFY Understanding voice of the customer Develop CTQs for the design Set targets Plan and launch project DESIGN Generate and evaluate concepts Create high level design Analyse and test high level design OPTIMIZE Develop detailed design parameters Optimise detailed design Create prototype Ensure robust design VERIFY Test and refine design Develop final design Set up for production rampup

Voice of the Customer (VOC)

The customer is any person or group that receives the product or service and they have specific expectations of what they want. Voice of the customer (VOC) is the expectations of the customers, expressed by them, explicitly or implicitly. Common VOCs are:

Easier access to service More features / functionality Ability to customize Easier to use Good service Faster response Reliable quality Lower cost

Translate VOC to CTQ

Once VOC is known, the next step is to translate it to CTQ (measurable goal).

 Six Sigma Roles and Responsibilities Textbook, Chapter 2, page no. 17 Critical to x (CTx) Requirements Textbook, Chapter 4, page 24 Business Performance Measures Textbook, Chapter 6, page no. 28 Voice of the Customer Textbook, Chapter 15, page 62

Define
Project Charter Graphic aids
SIPOC diagram, Gantt Chart, Work Breakdown Structure, PERT, Process Mapping

Measure
Data Collection Capability Analysis Measurement Systems Evaluate capability of measurement systems (Gauge R&R) Display of data Stem and Leaf plots, Pareto charts, Histograms, Scattered diagrams

Analyze
Common causes and assignable causes Hypothesis testing Non-parametric tests & ANOVA Regression analysis Control Charts FMEA

Improve
Mistake proofing/ Poke Yoke Waste Elimination Cycle Time reduction Kaizen

Control
Other Control Tools Statistical Process Control
Selection of control chart Attribute Chart Variables Chart