Motorola systematically improved processes by eliminating defects

Bill smith in 1986

6 Sigma & Standard Deviation

Signifies standard deviation of a population

Standard Deviation indicates variation or inconsistency

in any group of items

Example

Fast Food----Warm one day, Lukewarm on other day,

is variation
Airport …..Luggage in 5 minutes or 15 minutes
 INSPIRED
BY

Quality Zero
TQM
Control Defects
 Asserts

Continuous efforts to reduce

Variation in process output
is key to business success

Manufacturing and business processes

Can be measured ,analyzed ,improved
And controlled

Succeeding at achieving sustained quality

Improvement requires commitment from the
Entire organisation, particularly from top
Level management
Refers to the ability of highly capable processes to
Produce output within specification. In particular,
Processes that operate with six sigma quality
Produce at defect level below 3.4defects per million
Opportunities (DPMO). Six Sigma’s implicit goal is to
improve all Processes to that level of quality or better
Six Sigma stands for Six Standard Deviations from mean.
(Sigma is the Greek letter used to represent standard deviation in statistics)
Six Sigma methodology provides the techniques
and tools to improve the capability and reduce the
defects in any process.
 methodology

DMAIC DMADV
 methodology

Define
Measure
DMAIC Analyze
Improve
Control
 methodology

DMAIC

Define
Measure Define: the process improvement goals
Analyze that are consistent with customer
Improve demand and enterprise strategy
Control
 methodology

DMAIC

Define
Measure
Measure: the current process and collect
Analyze
relevant data for future comparison
Improve
Control
 methodology

DMAIC

Define Analyze: to verify relationship and causality

Measure of factors. Determine what the
Analyze relationship is,and attempt to ensure
Improve that all factors have been considered
Control
 methodology

DMAIC

Define
Measure Improve: or optimize the process based
Analyze upon the analysis using techniques
Improve like design of experiments
Control
 methodology

DMAIC
Control: to ensure that any variances are
corrected before they result in
Define defects. Set up pilot runs to
Measure establish process capability,
Analyze transition to production and
Improve thereafter continuously measure
Control the process and institute control
Mechanisms
 methodology

Define
Measure
DMAIC Analyze
Improve
Control
 methodology

DMADV

Define Define:
Measure the goals of design activity that
Analyze are consistent with customer
demands and enterprise strategy
Design
Verify
 methodology

DMADV

Define Measure:
Measure and identify CTQs (Critical
Analyze to qualities), product capabilities
Design production process capability
and risk assessment
Verify
 methodology

DMADV

Define Analyze
Measure
Analyze To develop and design alternatives,
Design Create high level design and evaluate
Design capability to select the
Verify Best design
 methodology

DMADV

Define Design
Measure
Analyze Details, optimize the design, and plan
Design For design verification. This phase may
Require simulations
Verify
 methodology

DMADV

Define Verify
Measure
Analyze The design, setup pilot runs, implement
Design Production process and handover to
process owners
Verify
 Other methodologies
DCCDI Define, Customer Concept, Design and Implement

CDOC Conceptualize, Design, Optimize, Verify

DCDOV
CDOC Define,
Conceptualize,
Concept,Design,
Design,Optimize,
Optimize,Verify
Verify

DMADOV Define, Measure, Analyze, Design, Optimize, Verify

DMEDI Define, measure, Explore, Develop,and Implement

IDOV Identify, Design, Optimize and Validate

I2DOV Invent, Innovate, Develop, Optimize, Validate

Implementation Roles
IMPLEMENTATION ROLES

YELLOW
BELTS

GREEN BELTS

BLACK BELTS

EXPERTS
MASTER BLACK BELTS

CHAMPIONS
EXECUTIVE LEADERSHIP
 Benefits

John Chambers CEO, CISCO

Generate One can be out of business.
Sustained Only way to continue double Digit
Success growth and retain a hold on
Shifting market is to constantly
Innovate and remake the organization
 Benefits

Getting everyone working in the same

Direction and focusing on a common
Sets Performance Goal………Customer
Goal for
Performance……..99.9997%
Everyone Excellent performance look pretty
week
 Benefits
Performance Goals—what you’d Get

For every 300000 letters delivered

with 99% with 6 sigma

3000 misdeliveries 1 misdelivery

Sets Performance
Goal for Out of 500000 computer restart
Everyone
4100 crashes < 2 crashes

For Every week of TV broadcasting

1.68 hrs of dead air 1.8 seconds

 Benefits

Jack Welch---GE
Enhances We want to make our quality so
Value to Special ,so valuable to our customers,
Customers So important to their success that our
Products become their only real
Value choice
 Benefits

Motorola
Accelerate the
Rate of Goal of 100x improvement in 4 years
Sets an example for ambitious, driven
Improvement Organisation to emulate
 Benefits

Allied Signal- honeywell

Promotes Learning
and Everyone talks about learning
Cross Pollination But few succeed in weaving it into the
Fabric of everyday life for so many
Employees…GE plastics to GE Capital
 Benefits

Allied Signal- Honeywell

Execute Introducing new products, launching new
Strategic Change Ventures, entering new markets, acquiring
New organizations- what were occasional
Business activities are now daily events
in many companies
 Benefits

Continuous Process
Improvement Design/
Resign

Statistical
Process
Control Analysis
Of
Variance
Process
Management
Balance
Scorecard
n of s
i g t
Des rimen
e
Exp Creative Voice of
Thinking The
Customer
6 sigma initiative include

E-commerce and Services

Enterprise Resource Planning
Lean Manufacturing
Customer Relationship Management
Strategic Business Partnerships
Knowledge Management
The process- Centered Organization
Globalization
Just in Time inventory/Production
 6 themes of 6 sigma

Theme One: Theme Two: Theme Thee:

Genuine Focus on Data and Fact Driven Process Focus,

Customer Management Management and
Improvement

Theme Six:
Theme Four: Theme Five:
Drive for Perfection,
Proactive Boundary less
Tolerance for Failure
Management Collaboration
?