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Student Learning Objective 6

Apply the commonly used quality systems and standards.

Learning Objective E

Compare Six Sigma to total quality management and ISO 9001.

Introduction

  • Superficial introduction to Six Sigma

  • Will be discussed again in Learning Objective 8 (Chapter 19)

Goals of Six Sigma

Six Sigma

The goal of Six Sigma is to increase profits by eliminating variability, defects and waste that undermine customer loyalty.

Six Sigma can be understood/perceived at three levels.

  1. Metric: 3.4 Defects Per Million Opportunities. DPMO allows you to take complexity of product/process into account. Rule of thumb is to consider at least three opportunities for a physical part/component - one for form, one for fit and one for function, in absence of better considerations. Also you want to be Six Sigma in the Critical to Quality characteristics and not the whole unit/characteristics.

  2. Methodology: DMAIC/DFSS structured problem solving roadmap and tools.

  3. Philosophy: Reduce variation in your business and take customer-focused, data driven decisions.

Six Sigma is a methodology that provides businesses with the tools to improve the capability of their business processes. This increase in performance and decrease in process variation leads to defect reduction and vast improvement in profits, employee morale and quality of product.

Here's an article with more detail on Six Sigma: What is Six Sigma?

Source: https://www.isixsigma.com/dictionary/six-sigma/

Overview of Six Sigma

Six Sigma: An Overview + Different opinions on the definition of six sigma + Six Sigma is a Philosophy + Six Sigma is a Set of Tools + Six Sigma is a Methodology + Six Sigma as a Measure + Six Sigma as a Metric + Six Sigma Structure

Source: https://www.slideshare.net/hakeemrehman/lean-six-sigma-green-beltnew

Six Sigma Measure

six sigma is a measure

Source: https://www.slideshare.net/hakeemrehman/lean-six-sigma-green-beltnew

Six Sigma Frameworks

ProgramSix SigmaLean Six SigmaDFSS
Focus/ThemeVariation, Defects, Cost of Poor QualityWaste/speed, cycle time, delivery cost of operationReliability and Robustness, Design features
MethodologyDMAICDMAICDMADV
Tools SIPOC, CTQ, SPC, FMEAN, DOE, QFD, CoQ, ANOVA, Hypothesis, Regression, MSA (R and R) 5S, Value Mapping, Time Study, TPM, Cellular Production, Takt Time, Poke Yoke VOC, QFD, FMEA, CTQ, Gage R and R, DOE, Reliability Analysis, SPC, Systems Engineering

Source: https://www.slideshare.net/hakeemrehman/lean-six-sigma-green-beltnew

Six Sigma DMAIC Process

Digital Six Sigma DMAIC Improvement Process

Source: https://www.slideshare.net/jagan339/dmaic-5464662

Design for Six Sigma

Product/Process DFSS - 14 Steps

Source: http://www.sbtionline.com.cn/Templates-SBTI/Solutions-%20Design.html

Team Member Roles

  • Master Black Belt. The highest level of Lean Six Sigma knowledge and experience. Often a full-time role mentoring Black Belts and coaching Lean Six Sigma Belts.
  • Champion Belt. The Champion Belts are senior members of the organisation who offer support to ensure the success of the project. Their role requires an understanding of the key concepts and methods.
  • Black Belt. Typically operate Lean Six Sigma projects as a full-time role within an organisation. They lead Green & Yellow belts & can overcome complex problems.
  • Green Belt. Trained to lead small Lean Six Sigma projects usually within one department. They can also assist Black Belts on larger projects.
  • Yellow Belt. Project team members with an understanding of key concepts and basic tools. Their role is to assist Green Belts.
  • White Belt. Team members who have been prepared with a basic knowledge of Lean Six Sigma so that they can support but not actively participate in projects.

Lean Six Sigma Team Roles

Source: https://www.100pceffective.com/blog/strength-in-numbers-the-role-of-support-in-lean-six-sigma-success/

Early History of Six Sigma

history of six sigma

Source: https://www.slideshare.net/oeconsulting/six-sigma-overview-by-allan-ung-operational-consulting

Difference Between TQM and Six Sigma

TQMSix Sigma
A business philosply which explains the ways of managing people and business processes in order to ensure customer satisfaction at every stage of the business A tool of measuring the quality which drives towards perfection

Source: https://www.differencebetween.com/difference-between-tqm-and-vs-six-sigma/