Professional Documents
Culture Documents
Cost Reduction
Value Creation
Reduction in variation
Elimination of defects
Improvement in yield
Example: GE’s Medical System division (GEMS) used Six Sigma design
techniques to create a breakthrough in medical scanning technology. Patients
can now get a full body scan in half a minute, versus three minutes or more with
previous technology. Hospitals can increase their usage of the equipment and
achieve a lower cost per scan, as well.
Six Sigma approach is to find out the root causes of the problem,
symbolically represented by Y = F(X).
• Waste prevention
• Defect reduction
• Cost savings
Sigma, represented by the Greek alphabet ‘σ’, stands for standard deviation
from the ‘mean’. ‘Six Sigma’ represents six standard deviations from the
mean*.
Mean: It is the simple average of data. * Details will be provided in our Six Sigma Black
Standard deviation: It is a measure of variability of data. Belt and Green Belt course.
* Details will be provided in our Six Sigma Black Belt and Green Belt course.
Please note: As the sigma level increases, the defect percentage decreases, which improves the
efficiency of the process.
Champion
Black Belt
Green Belt
Project Team
Master Black Belts - Master Black Belts are in-house experts selected
by Champions. They manage project selection and human resource
training with the help of Champions. They train Black Belts and Green
Belts in Six Sigma implementation.
Black Belts - Black Belts are those who apply the tools and techniques
and knowledge of Six Sigma principles to a given project of an
organization. They are responsible for accomplishing the tasks
entrusted to them by Champions and Executive leadership. They
dedicate all of their work hours on Six Sigma implementation.
Project Team - They are the employees who work on the Six Sigma
project. It includes the Project Manager as well. Project team members
need not be a Green Belt or Black Belt.
Employees – they are the people involved in the six sigma initiative in
the organization.
End users – they are people who actually use the product or service.
End users can also be customers.
*The Inputs, Tools and Outputs are covered in more detail in our Six Sigma Green Belt and Black Belt course .
*The Inputs, Tools and Outputs are covered in more detail in our Six Sigma Green Belt and Black Belt course .
*The Inputs, Tools and Outputs are covered in more detail in our Six Sigma Green Belt and Black Belt course .
*The Inputs, Tools and Outputs are covered in more detail in our Six Sigma Green Belt and Black Belt course .
The Analyze phase is used to identify few vital causes from a list of
potential causes obtained from the Measure phase, actually affecting
project outcome using six sigma methodologies. The data collected in
the Measure phase are examined to determine a prioritized list of the
sources of variation.
Check sheets
Histograms
Pareto diagram
Scatter diagram
Control charts
Before we get into details of the 7 basic tools, let us familiarize with the
concept of data types.
Data can be broadly categorized into two types: Continuous data and
Attribute (discrete) data.
Check sheets are very important tool for data collection. Inputs gathered
from check sheets can be used for creation of Pareto diagrams,
Fishbone diagrams etc.
Collect the frequency of data for the items being measured. Record
each occurrence directly on the right side of the Check Sheet as it
happens.
Tally the data by totaling the number of occurrences for each category
being measured
Total
Arrange the data in ascending order such that the minimum and
maximum value can be identified
A sample diagram is
given here where
the raw data are
displayed in the
form of a histogram.
Helps clarify several process steps and process flow which may not be
understood clearly before.
Helps all members of the team gain appreciation for the work being
done by others in the team.
Oval: represents the start of stop of a process map, also used to depict
if the process map continues in another page.
Define the process and its boundaries, including the start and end
points.
Try to find out existing process maps which may already be in existence
in the company.
Map all the “As-is” high level processes i.e. processes as they exist now.
This will create an awareness within the team about the processes in
existence currently, and also let all team-members understand the
contribution from others. This is the “As-is” Process map.
Based on the inputs from cross functional team, map all the “To-be”
processes. This is the “To be” Process map.
It is the simple process map along with the various functions displayed
on the left side of the diagram.
This tool is employed where there is only one problem and the possible
causes are hierarchical in nature.
This diagram is also known as Fish bone diagram (because of its fish
bone like structure) or Ishikawa diagram.
Identify the major categories for causes of the effect, which form the
main branches of the diagram.
Ensure that the team have a good knowledge of the process and
understand the problem under study.
Write the names of categories above and below the horizontal line. Start
with high level groups and expand each group (up to 3 or 4 levels).
Write down the detailed cause data for each category
Possible causes
Effect
Dr. Juran termed those few contributors which account for bulk of the
effect as ‘Vital few’.
180 90.0
160 80.0
140 70.0
120 60.0
100 50.0
40 20.0
20 10.0
0 0.0
From this we can see that only the first four complaint category (Room
service, Housekeeping, Reservation, Food and Beverages) constitute
80% share of the total complaints. Hence these four areas need
immediate attention to improve the process performance.
90
80
70
60
50
Y
40
30
20
10
0
0 5 10 15 20 25 30 35 40 45
X
From the above scatter diagram we can see that the factors X and Y are
having a negative liner relationship. Individual data points are plotted as
bullet points and the trend line indicates there is a linear relationship.
Common causes of variation are natural in the process. They are small
in magnitude and difficult to identify / remove from the process.
Lets take a look at a sample control chart. Data obtained from the process
is plotted in a chart as shown below.
Upper and Lower Specification Limits (USL and LSL): These are
obtained by taking the voice of the customer. A process would satisfy
customer requirements if it falls within the specification limits.
Upper and Lower Control Limits (UCL and LCL): These are calculated
from the process data and if all the process data stays within the control
limits then it is very likely that the variation is inherent in the process i.e.
common cause of variation. UCL and LCL lie within the upper and lower
specification limits. If the process data lies outside the control limits,
then it is a special cause of variation.
DMADV is used when the existing product or process doesn't meet the
level of customer specification or six sigma level even after optimization
with or without using DMAIC.
VALIDATE the design performance and its ability to meet the customer
needs