Six Sigma for Safety Officers

Mohamed Rawidean Mohd Kassim

dean@mimos.my
 Introduction
• Developed by Bill Smith of Motorola, USA in 1987.

• The objective of Six Sigma is to improve the quality

of processes by identifying and removing
the causes of defects.

• In safety, these process defects can be unsafe

behaviors, incorrect procedures or equipment
failures, all of which can result in injury.
 Six Sigma Methodology
• Six Sigma is a highly systematic process focusing on
developing and delivering near perfect products and services.

• Uses the DMAIC method for process improvement

- Define,
- Measure,
- Analyze,
- Improve,
- Control

• Uses the DMADV method for new products development

- Define,
- Measure,
- Analyze,
- Develop / Design,
- Verify
Benefits of Six Sigma
• Reduced lead time
• Improve quality & productivity
• Reduced inventory
• Reduced waste
• Optimized workforce without new hiring
• improved customer service
• Enhanced documentation
• New innovations
• Increase communication between staff & managers
• Reduced operation cost
• Increased growth & benefit
• Customer satisfaction & retention
• Efficient strategic management
 Six Sigma vs TQM
Six Sigma TQM
Focuses on strategic goals and Focuses on quality
applies them to cost, schedule and
other key business metrics (safety)
Driven by tangible improvements of a Motivated by quality idealism
corporate performance measure
Emphasizes on breakthrough rates of Emphasizes problem solving
improvement

Focuses on world class performances Focus on standard performance,

e.g. 3.4 PPM defect rate e.g. ISO 9000
Provides tools and techniques and Provides tools and techniques
clearly defined framework for using with no clear framework for
them to achieve results (DMAIC) using them effectively
Elements of Six Sigma
DMAIC
• Define project and identify process
Define

• Evaluate Measurement Systems and resulting data

Measure • Estimate process capability

• Identify root causes

Analyze

• Performance improvements
Improve • Test effectiveness of improvements

• System to maintain gains - sustainability

Control
DMADV
Six Sigma Tools
DEFINE – Identify the Problem
• Project Charter, SIPOC, Voice of Customer (VOC), CTQ

MEASURE – Quantify the Problem, Current Data

• VSM, Priority Matrix, Cause-Effect Diagram

ANALYZE - Determine Root Causes

• Graphical Charts, Statistical Tools, 5 Whys

IMPROVE – Implement & Verify the Solutions

• Brainstorming, 6 Thinking Hats, Pilot Plan

CONTROL – Maintain the Solution

• Best Practices, SOP, Control Plan & Charts
 SAFETY COMPONENTS
Behavioral-based
Safety

Work Methods Human Error

Design

Safety Cultural
Safety Training Assessments

Safety Audits Safety Leadership

 SIX SIGMA vs. 4IR

• New powers to analyze vast quantities of structured

data from 4IR technologies are already being exploited
by Six Sigma practitioners.

• It seems that while 4IR data will inevitably increase the

impact not just of Six Sigma but of quality program
generally, which could create tensions with existing
tools and techniques.

• So, practitioners of Six Sigma could be challenged to

adopt and adapt to 4IR or be overtaken.
 CONCLUSIONS

• Leading safety activities should be assessed on an

ongoing basis.

• Need to discover the REAL reasons for failure and

success.

• Six Sigma tools, including DMAIC and DMADV can

provide significant and sustainable improvements.

• Six Sigma practitioners should exploit 4IR

technologies for safety management.