Learn Six Sigma

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What Is Sigma?

  • Letter in the Greek alphabet

  • Statistical unit of measure

  • Metric

  • Benchmark

-Measure of variation

-Measure of quality

-Measure of process capability

-Measure of performance

What Does Six Sigma Mean To You?

Six Sigma Is A Business Philosophy

“Six Sigma is not an improvement program.  It is instead a business philosophy that employs a step-by-step approach to reducing variation, increasing quality, customer satisfaction, and, in time, market share.”

“Six Sigma is about the quality of business, not the business of quality.”

  – Dr. Mikel Harry

Six Sigma Is Different From Past Quality Programs In That It…

  • Is strongly driven from the top

  • Requires full time practitioners who receive significant training

  • Is a systematic project based approach that monitors projects

    to closure

  • Scopes problems to create discrete and cleanly finite projects

  • Aligns customer needs and business goals

  • Is entirely data and metric driven

  • Ensures improvements are validated statistically

  • Changes business measurements

  • Changes the role of finance

  • Sustains the gains

  • Results in demonstrable success

  • Improves competitiveness

…and is bottom line focused and led by executives.

Six Sigma Benefits

  • Enables success in a world of intensified competition and

    declining margins

  • Ensures the quality necessary to satisfy increasingly

    demanding customers

  • Provides the means to become the best in the world

  • Establishes a standard language and approach across all functions and lines of business

  • Helps develop the next generation of leaders

Directly linked with business objectives.

Premise Of Six Sigma

  • The basic premise of Six Sigma is that sources of variation can be:

-Identified

-Quantified

-Eliminated or Controlled

  • Focused on strategic or core processes

  • Data-driven

-Measurements focused on the right things

  • Customer-driven

Variation is the enemy!

Getting To Six Sigma

“Voice Of Process” vs. “Voice Of Customer”

Voice Of Process is independent of the Voice Of Customer

Goals Of Six Sigma

Meet Customer Target and Specifications

Six Sigma As A Statistical Measure

In a Six Sigma process, Customer Satisfaction and Business Objectives are robust to process shifts.

Can We Tolerate Variability?

  • There will always be variability present in any process

  • We can tolerate variability if:

-The process is on target

-The total variability is relatively small compared to the
process specifications

-The process is stable over time

Is 99% Good Enough?

Will Inspection Help?

Task:  You have 60 seconds to count the number of times the sixth letter of the alphabet appears in the following text:

“The necessity of training farm hands for first class farms in the fatherly handling of farm livestock is foremost in the eyes of farm owners.  Since the forefathers of the farm owners trained the farm hands for first class farms in the fatherly handling of farm livestock, the farm owners feel they should carry on with the family tradition of training farm hands of first class farmers in the fatherly handling of farm livestock because they believe it is the basis of good fundamental farm management”.

What Do We Know About Our Process?

We don’t know what we don’t know.

We can’t act on what we don’t know.

We won’t know until we search.

We won’t search for what we don’t question.

We don’t question what we don’t measure.

Hence, we just don’t know.

  – Mikel Harry

The Power Of Questions And Critical Thought

  • To better understand our process we need to ask questions

-Same questions – Same answers

-Changing the result means we have to change the question

-As questions arise, visions emerge, direction becomes apparent

  • To lead change, Black Belts have to be able to ask critical questions

-Of the organization

-Of process experts

-Of process authority

  • Questions may often drive behavior

Data: The Foundation Of The Six Sigma Tools

Data is derived from objects, situations, or phenomenon in the form of measurements.  Data is used to classify, describe, improve, or control objects, situations, or phenomenon.

Levels of Analysis:

  1. We only use experience, not data

  2. We collect data, but just look at the numbers

  3. We group the data so as to form charts and graphs

  4. We use census data with descriptive statistics

  5. We use sample data with descriptive statistics

  6. We use sample data with inferential statistics

What level are we?

Six Sigma...The Analytical Toolset To Drive Data-driven Decisions

Some Six Sigma Tools:

  • Critical To Tree (CT Tree)

  • Process Mapping

  • Graphical Techniques, e.g., Pareto Analysis

  • Measurement Systems Analysis

  • Rational Sub-grouping

  • Capability Analysis

  • Hypothesis Testing

  • ANOVA (Analysis Of Variance)

  • Regression

  • DOE (Design Of Experiments)

  • Response Surface Design

  • SPC (Statistical Process Control)

MINITAB® statistical software is the toolbox for most of these tools.

Overall Problem Solving Approach

Dynamics Of Execution Strategy – The Funnel Effect

Value Defined By The Customer

  • Customer defines value:

-For something to add value, it must

  • Change the product or provide a service

  • Meet quality requirements

  • Be available when the customer needs it

  • Be something the customer will pay for

  • Six Sigma components of value:

-Cost – What the customer will pay, what is our margin

-Quality – What is the cost of poor quality

-Delivery – Characteristics of our process that impact delivery

Business survival is based on how well we satisfy the customer.

Process Focus Of Six Sigma

  • Inputs (X1, X2 . . . Xn)

  • Independent

  • Cause

  • Control

  • Output

  • Dependent on Input

  • Effect

  • Monitor

Determining the critical Xs and controlling the Xs to guarantee the Ys.

How Y=f(x) Relates To A Process

Control the INPUTS to achieve the desired OUTPUTS that satisfy our customers’ expectations.

Why Are Most Companies At 3 – 4 Sigma?

Most companies

  • Past success has bred arrogance

  • Dependence on inspection and rework

  • Reliance on trial and error

  • Rewarding fire – fighting behavior

  • Little focus on quality metrics

  • Functional silos inhibit collaboration

Taking The Breakthrough Strategy Leap

What’s needed to make the leap?

  • Conviction in the opportunity

  • Belief in the methodology

  • Openness to challenge “status quo”

  • New skills, tools, and information

  • New behaviors for management

Harvesting The Fruit Of Six Sigma

© 1994 Dr. Mikel J. Harry – V4.0

The Breakthrough Strategy

Six Sigma Roles And Responsibilities

Job Description Of A Black Belt

  • Team’s technical Six Sigma expert

  • Deliver results on time

  • Identify barriers

  • Lead team to execute projects

  • Report progress to leadership

  • Solicit help from Champions

  • Influence without direct authority

  • Stimulate Champion thinking

  • Determine appropriate tools to apply

  • Identify project resources (Project Management)

  • Get input from knowledgeable operators, first line supervisors, teams and coaches

  • Teach and coach Breakthrough Strategy methods and tools

  • Manage project risk

  • Ensure results are sustained

Importance Of Visible,Top-down Leadership

  • Six Sigma only works when Leadership is passionate about excellence and willing to change

  • Fundamentals of Leadership

-Challenge the process

-Inspire a shared vision

-Establish top level goals

-Enable others to act

-Model the way

-Encourage the heart

  • Six Sigma is a catalyst for leaders

Deliverables For Course Completion

  • Attend and complete all required Black Belt training

  • Maintain Project/Evidence Book

-Copy of the final project report

-Demonstration of appropriate use of tools

-Deliverables for each week of training

  • Reviewed at the end of each week of training and contingent upon status of individual project

-Conclusions and next steps

-Lessons learned

-Copies to Process Owner and Champion upon completion
of project

  • Certification is determined in conjunction with your organization

Objectives Review

The participant should be able to:

  • Describe the Six Sigma approach to solving business problems by discussing the vision, purpose, goals and tools of Six Sigma

  • Describe the phases of the Six Sigma Breakthrough Strategy

  • Explain integration of Six Sigma in an organization

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Learn Six Sigma

What Is Sigma? Letter in the Greek alphabet Statistical unit of measure Metric Benchmark -Measure of variation -Measure of quality -Measure of process capability -Measure of performance What Does Six Sigma Mean To You? Six Sigma Is A Business Philosophy “Six Sigma is not an improvement program.  It is instead a business philosophy that employs

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