The Cost of Poorly Performing Processes – Need for Six Sigma
Prior to the introduction of Six Sigma philosophy, there was a debate as to whether Six Sigma is a goal worth pursuing. Many experts in the area of quality believed that wastage was a way of life. Trying to eliminate wastage would cause more wastage. They believed that it was possible to eliminate waste but…
What is Six Sigma ? – A Tool to Conquer Variability
Definition of Six Sigma Six Sigma is not a mere methodology or a quality tool. It is a philosophy i.e. a systematic way of thinking to solve quality problems. Six sigma involves use of statistics to convert raw data into facts about how the processes of the organization are being run. The thrust is on…
What Six Sigma is Not ? – Fallacies about Six Sigma
Six Sigma has really become a management buzzword. A lot of people use it in very different contexts. As a result a variety of meanings have been conjured up for the very simple six sigma process. To simplify matters and to ensure that the readers have an accurate understanding of what the Six Sigma process…
Six Sigma is a process oriented methodology designed to improve business performance by improving specific areas of strategic business processes. There are 2 different methodologies available for carrying out improvements in processes or operations.
Improvements can be of two types: improving the existing process or designing a new process altogether. When we have an existing process and we want to improve the process we deploy the DMAIC methodology. While designing a new process or completely revamping the existing process the Design for Six Sigma or IDOV methodology is deployed.
| DMAIC | DFSS |
| Structured and iterative process improvement methodology | Rigorous approach to designing processes that will exceed customer expectations |
| Focus on defect reduction | Focus on defect prevention |
| Define | Define the problem. Define the customer(s) and the requirements. Define the current capability. Define the key processes that will have the greatest impact on customer. |
| Measure | Identify the statistical measures to monitor the key process. Set up the data collection plan. Measure the process |
| Analyse | Determine the analysis tools and methods to be used. Summarize the data measured. Run the analysis and determine the root causes, effects, etc. |
| Improve | Improve and Implement. Focus on developing process/technology to improve the root cause. Test the method on sample process and validate the improvement. |
| Control | Standardize and document the process and implement the plan. Monitor the process and feedback the results back to the process for continuous improvement. |
| Identify | Develop a team. Create team charter. Gather VOC. Perform competitive analysis. Develop CTQs and formally tie design to VOC. |
| Design | Identify functional requirements. Develop alternative concepts. Evaluate alternatives and select a best-fit concept. Deploy CTQs and predict sigma capability. |
| Optimize | Determine process capability. Develop detailed design elements. Predict performance. Optimize design. |
| Verify | Test and validate the design. Share feedback with manufacturing and sourcing to improve future manufacturing and designs. |
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