Six Sigma is a quality system that strives to achieve near perfect standards. Six Sigma refers to a data-driven, disciplined methodology that eliminates defects in any process, whether it is manufacturing, transactional, or product.
Six Sigma was established as an estimation method by Carl Friedrich Gauss (1777-1855), the inventor of the normal curve. Six Sigma in item variety is an estimation method. Walter Shewhart explained that three Sigma from a mean is the point at the process requires correction. Many estimation principles have been developed (Cpk and Zero Imperfections). The term “Six Sigma”, however, was created by Bill Smith, an engineer at Motorola. Mikel Harry had also collaborated with Bill Smith to create and codify a research report about the new quality control system. The report highlighted the interdependence between product performance on the market and manufacturing adjustments. It was clear from the report that the production process should be as smooth and non-conformistic as possible. This report was revolutionary because it opened the door to the use of ‘logical filters’ to solve problems. Motorola’s then CEO Bob Galvin was a pioneer in this system. With his support, this four-stage logic filter became the basis of Six Sigma. These four stages were called Measure, Analyze and Improve, as well as Control.
Six Sigma’s goal is to use Six Sigma projects and process improvements to improve processes and reduce variation. Two sub-methodologies of Six Sigma are used to achieve this.
DMAIC, an acronym for Define.
Define the system, customer voice, their requirements and project goals.
Take stock of key elements and gather relevant data.
Analyze data to verify cause-and effect relationships. Determine the relationships and ensure that all factors are considered.
Optimize the current process or make it more efficient. Data analysis can be done using methods such as experiment design, poka tie or mistake proofing. Also standard work can be done to create a new process.
You can control the future state process in order to correct any deviations. Monitoring the process is possible by using control systems such production boards, statistical control and visual workplaces. This is repeated until you reach the desired level of quality.
DMADV – Five phases of the DMADV (Design For Six Sigma) project methodology are included:
Design goals should be consistent with the enterprise strategy and customer requirements.
Measuring and identifying CTQs (characteristics that have Critical Quality), assessing product capabilities, production process capabilities, and evaluating risks.
Analyze and develop design options.
Consider a better alternative that would be most suitable for the analysis made in the preceding step.
Check the design, create pilot runs and implement the production procedure.
It is customer-driven. It considers the entire production process, not just the end result. It is proactive and not reactive. This means that it aims to discover ways to improve the process, even before flaws or defects are discovered. The Six Sigma quality certification is a prized achievement for small businesses. It is especially useful for specialty manufacturing firms that produce precision goods, like medical technology.
Six Sigma applies to all aspects and phases of the production planning and production process. However, this can cause rigidity in bureaucracy and delays which can hinder creativity and lead to delays.
Sometimes customer focus can be too extreme. Internal quality-control measures may not make sense for a company because the goal is to achieve Six Sigma-stipulated consumer satisfaction. A cheaper measure may have a higher defect rate than a more costly measure, which could be rejected to make way for a better measure that achieves Six Sigma but has a negative impact on profitability.
Implementing six-sigma in a small business is very expensive.
Six Sigma certification is only possible if employees are trained by Six Sigma institutes. Although a company may not be certified, it is essential to have sufficient training to fully understand Six Sigma and apply it to specific business processes. Even for one employee, many small businesses can’t afford this training. Six Sigma is a complicated system that requires small businesses to be creative and agile.
