Introduction

Six Sigma is a tool to reduce process variance and to reduce defect levels. It is very important to change the mindset and look at our products and processes from customer perspective.

Six Sigma provides a statistical measure to evaluate capability of a process. If a process has 3.4 defects/non compliance per million opportunities, then we could state that the probability to pass on a good or quality product to the customer is 99.99966%. In other words, we could say that the process is performing at 6 Sigma Level.

Six Sigma requires attaining operation excellence by continuously improving our services to the customer with the help of scientific, systematic and fact-based approach.

Six Sigma provides a set of tools designed to reduce variation in processes and operations so that we could provide a consistent performance. It is a business strategy to provide better services to the Customer to win their confidence and increase business opportunities. Six Sigma tells us not to focus on the end product but rather focus on the process that produces the product. We look at the problem within the process and tackle that problem which would give us better product.

So, Six Sigma is about

• Focus on the Customer
• Data or Fact Based – Your Data should always talk about your problem
• Process Focused

Data collection and classification is necessary in a Six Sigma project to calculate the Sigma Value. A Sigma Value is a statistical measure to show the Current Process Capability as well as improved Process Capability after the improvement is done.

Edward Deming is a Quality Guru, who says that 85% of the reasons for failure to meet Customer expectations are related to deficiencies in systems and processes, rather than the employee.

The idea that failures in the process are primarily related to problems in the system, rather than to the people running it, is a philosophy, which is at the heart of process improvement. Given this approach, we must try to discover the true cause[s] for why process is not performing adequately and we need not look at the people as the primary suspects. Rather, we would investigate other possible sources, which might be causing the process not to function effectively or as the way we expect.

Six Sigma and Other Quality Models

ISO helps us to develop and implement processes. It also makes sure that we use the same processes across departments so that the product is produced with the help of same process over a period of time. It ideally states whatever you do should be documented as your project plan or whatever is documented you should do the same.

CMM and CMMI helps us to improve the processes in terms of maturity, re-usability and reduction in redundancies by focusing on certain key areas like Quality Assurance, Quantitative Process Management, Defect Prevention, Technology Change Management etc.

Both CMM and CMMI models provide guidelines and frameworks to develop processes but it need guidance and details of exact tools and techniques to be used. Six Sigma provides us a set of tools and techniques to be used to improve a process performance with the benefits mentioned earlier. Six Sigma provides and drives a customer focused approach.

ISO, CMM and Six Sigma are contributing to each other and any organization should use all of them to get optimum benefit within a short time period.

Six Sigma Project Types

A Six Sigma project is done either to improve upon an existing process or to introduce a new process altogether. Accordingly these are classified as DMAIC or DMADV approach of Six Sigma Project.

Every organization would like to know the benefit that each Six Sigma Project gives back to the organization. This is called the Savings out of a Six Sigma Project. This could be identified in P/Days Savings, Dollar Savings or Savings in Indian Rupee. Savings out of a Six Sigma Project is always measured per annum.

Any improvement from a Six Sigma Project has to be constantly monitored to ensure that the improvement is sustained. Monitoring may be for 4-6 months would be a good target.

Six Sigma Certifications and generic roles & responsibilities

White Belt:

• Can work on local problem-solving teams that support overall projects, but may not be part of a Six Sigma project team.
• Understands basic Six Sigma concepts from an awareness perspective.

Yellow Belt:

• Aware of the Six Sigma Terms and their usage
• Helps Green Belts in Six Sigma Project Execution and management
• Participates as a project team member.
• Reviews process improvements that support the project.

Green Belt:

• Experts of the Six Sigma Terms and their usage
• Spend a portion of their time completing six sigma projects.
• They apply Six sigma methodologies to solve problems assigned to them by black belts and can also work in groups when assigned large projects.
• They also continue to work on their regular work roles and responsibilities.
• Typically green belts spend around 10% to 50% of their time on projects.
• At the end of the training and certification process, the Six Sigma Green Belts will be able to:
• Implement the Six Sigma methodologies in an organization
• Work on Six Sigma projects as a team with other greenbelts under black belts.
• Use of Basic Statistical tools.
• Leads Green Belt projects or teams.

Black Belt:

• The Certified Six Sigma Black Belt is a professional who can explain Six Sigma philosophies and principles, including supporting systems and tools.
• A Black Belt should demonstrate team leadership, understand team dynamics and assign team member roles and responsibilities.
• Black Belts have a thorough understanding of all aspects of the DMAIC model in accordance with Six Sigma principles.
• They have basic knowledge of Lean enterprise concepts, are able to identify non-value-added elements and activities and are able to use specific tools

Master Black Belt:

• Trains and coaches Black Belts and Green Belts.
• Functions more at the Six Sigma program level by developing key metrics and the strategic direction.
• Acts as an organization's Six Sigma technologist and internal consultant.

Parties to a Six Sigma Project