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SIX SIGMA - eBOOK - SMALL SIZE
SIX SIGMA - eBOOK - SMALL SIZE
A GUIDE TO BECOMING
A LICENSED SIX SIGMA
PROFESSIONAL
Comprehensive guide on the importance of
getting a Six Sigma certification.
A S T E P - BY- S T E P G U I D E
simplilearn
Table of Contents
How to Choose the Right Training Partner for Six Sigma Certification 10
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What is Six Sigma?
The fact that you are reading this book implies that you already have a working
knowledge of what Six Sigma(link) is and its importance to you and to the companies
and industries around you. For professionals who haven’t yet decided upon taking up a
certification, this guide helps in decision making by revisiting the principles of Six Sigma
and the goals that certification seeks to achieve.
Understand in its most basic sense, Six Sigma is a rigorous and systematic method of
improving operational performance by leveraging various tools to identify and eliminate
defects. This method has direct and tangible applications in almost all manufacturing
processes but it can also be used to find bottlenecks and improve the performance in
service-related organizations.
The whole concept behind Six Sigma can be summarized into three important tenets:
1
Reducing process variation is the key to making
processes predictable and stable. Six Sigma is a
rigorous and
systematic method
2 Process variations in manufacturing and service-based
of identifying
businesses are products of characteristics or inputs that defects and
can be measured, analyzed, controlled and improved. eliminating them
in manufacturing
3 The success of the Six Sigma approach and sustaining and service-related
the achieved results requires organization commitment
and support of top-level management in any company.
processes.
Six Sigma puts a premium on aspects of the process that can be measured and quantified. As a
result, this makes the financial returns easy to assess so the progress of the quality improvement
project can always be tracked and assessed against the associated costs and goals.
Six Sigma is a method that is strongly driven by management support and leadership. It is a cultural
transformation and not a one-off project. Thus, it has a higher chance of sustaining results versus
other methods.
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Six Sigma emphasizes the importance of decision-making based on data which can be verified and
tested by statistical methods. This eliminates the subjectivity of the decision-making process and
ensures that decisions are backed by evidence and not assumptions.
Making these attributes possible is the cornerstone of the Six Sigma approach best represented by the acronym
DMAIC. This stands for Define, Measure, Analyze, Improve and Control. These five steps form the backbone of the
Six Sigma approach and is cyclic in nature. This means that process improvements never really end; instead, the
results achieved by a previous improvement project forms the baseline for a succeeding project that seeks to
build on top of the most recent successes.
How is the process defined and How can the causes of the
how are defects measured defects be eliminated
Each of the five steps in the DMAIC method are supplemented by proven tools that make the process
repeatable and systematic. Examples of these include statistical tools like variance analysis, linear modeling,
ANOVA tests, correlations, regression analysis and fitting, and scatter diagrams and boxplots. Other methods
extensively used in Six Sigma include cost-benefit analysis, Design of Experiment, control charts and control
plans, root cause analysis, Why-Why, FMEA, value stream mapping, and Pareto charts among others.
The importance of Six Sigma in today’s results driven paradigm cannot be overstated. As a quality management
professional, you know that efficiency translates into costs. By making processes more effective through
reduction of defects and improvements in yield, companies can make more money and improve their financial
bottom line. And this is best achieved using the proven principles and methods in Six Sigma.
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What is the Difference between Lean and Six Sigma?
Many people often confuse Six Sigma and Lean as the same thing. They are not.
As a quality management professional, it is very important to know the difference between the two so you can
apply the relevant concepts accordingly. Lean focuses on the eponymous idea of becoming “lean” and this is
expressed as generating the most value for the least amount of work. Anything in the process chain that does not
generate value is considered “wasteful” and therefore detrimental to the overall bottom line. Conversely, eliminat-
ing wasteful processes can lead to reduced production costs and a more efficient organization.
In contrast, Six Sigma focuses on the idea of reducing process variations in order to reduce defects in the process.
The concept of “reducing variation” is the reason why statistics feature heavily in Six Sigma methodologies.
The backbone of Lean is outlined by the seven different types of wastes as developed
by Toyota in the 1980s. The seven wastes in Lean are:
07 Motion
As a result, statistics plays a more “toned down” role in Lean and is largely superseded by Value Stream mapping,
Kanban pull systems, and Poke-Yoke concepts.
A short table summarizing the characteristics of Lean and Six Sigma is shown.
Primary Interest Reduce waste and smooth flow Reduce variation to reduce defects
Secondary Effects Less inventory, fast throughput, better Improved quality, better perfomance,
perfomance, more uniform output, less reduced waste, less inventory, faster
variation, improved quality throughput, uniform process output
Scope and Scale Quick and initial gains, ongoing Complex problems that require indepth
improvements. Suitable for everyone analysis; Cross-functional Specialists.
and every part of the business.
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The concepts of Lean tend to appeal to a variety of organizations from different industries because it can be
readily adopted as a cultural shift in thinking. Six Sigma, on the other hand, appeals to tech and manufacturing
companies which already have an affinity for statistics and data management. In this context, Six Sigma
provides a framework through which the in-house statistical knowledge can be leveraged and targeted towards
process improvements that help increase yield by reducing defect.
Nowadays, Lean and Six Sigma are more intertwined than ever before, with concepts and methodologies from
both merging into one consolidated approach for many companies. Lean is used to develop the general cultural
mindset necessary to put focus on quality and process improvements, and then Six Sigma is brought in to drive
objective data-based decisions for reducing variation and defect.
Quality management professionals have the option to train in either Lean or Six Sigma, but can also combine
both by taking up Lean Six Sigma training and certification courses. For the purpose of this book, we are
focusing on the Six Sigma certification process only. Simplilearn offers online and classroom courses for Six
Sigma [link] & Lean Six Sigma certification.
A Six Sigma practitioner is a professional process improvement expert. As a professional, you are expected to
own the management of quality processes in organizations and drive the process forward to achieve the target
goals. You are expected to be well-versed in the details of each step, and demonstrate expertise in using the
tools and concepts necessary to make the process a success.
Master
Black Belt Experts and culture-changes, train and
mentor Black Belts/Green Belts
Black
Belt Lead Six Sigma project teams,
enable statistical decision making
Green
Belt Carry out Six Sigma projects related to
their jobs, ideate, analyse & recommend
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Organizations look to quality management professionals to guide their employees on a path towards continuous
improvement. In this regard, your leadership in mentoring the team assigned to you, as well as your technical
proficiency in using all the tools available at your disposal should be well established.
So, how does one acquire the skills necessary to become a Six Sigma practitioner and quality management
professional? This is where the Six Sigma certification process becomes an important step for establishing your
qualifications and expertise.
Six Sigma qualifications are classified into different levels called “belts” mirrored from the different belt colors in
martial artists. Each belt corresponds to a different level of skillset, responsibility, and expectation. The belt
classifications also correspond to different roles during the implementation phase of a project that utilizes the
Six Sigma methodology.
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Completing a Six Sigma certification process
is crucial because it is the foundation of a
successful career as a Six Sigma practitioner.
Nowadays, it is virtually impossible to be
hired by an organization as a Six Sigma
expert without the corresponding
Getting a Six Sigma
certification and experience. Similar to how certification demonstrates
engineers or doctors or lawyers cannot
practice their respective profession without
your commitment as a
obtaining a license, Six Sigma practitioners quality management
professional to improve
are also assessed based on their
qualification beginning with their
certification level. In addition, getting
certified also reflects your commitment as a
your analytical skills and
quality management professional to enhance your business
improving your analytical skills and enhances
your business acumen. A Six Sigma acumen.
certification allows you to stand out from the
crowd.
From a career perspective, this will open plenty of doors for you. Many Six Sigma experts are often hired as
a consultants to help start-up Six Sigma projects in a company or provide coaching and mentorship to
newbie Six Sigma practitioners. Others are hired to review existing processes and propose improvements
where necessary – much like a troubleshooter or a problem-solver add who is impartial and untainted by
existing organizational culture.
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There are also instances when organizations, particularly tech and manufacturing companies, hire engineers or
other professionals on the basis of their Six Sigma qualification. Having passed a green belt certification process,
for example, you are already expected to be well-versed with different methods of analyzing problems to reduce
cost, boost revenue, streamline inefficient processes, or simply have the ability to think through problems in a
logical manner.
In addition, a black belt is almost always an unassailable qualification for getting hired into management
positions. Black belts are expected to have demonstrated considerable experience in solving complex problems
and managing a larger group of experts from different fields in order to systematically remove bottlenecks,
weaknesses, and inefficiencies in the process. This is always taken to be a sound qualification as a manager who
can look at the bigger picture, integrate and manage different specializations and foster teamwork to make them
collaborate, and then drive projects to achieve results for the organization or the client.
A Six Sigma certification gives you a bankable edge when looking for work as
a quality management professional.
Becoming a recognized Six Sigma professional sets you up for more career opportunities
whether as a process improvement specialist, Six Sigma team leader or mentor, or even as
someone qualified for a higher management position.
So now we ask the most important question in this book: How can one get Six Sigma certified?
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Getting Six Sigma Certified: The Essential Steps
Next, you will have to pass an exam to prove you have learned the relevant concepts that are expected for
someone certified in the belt that you want to get.
Once you pass the exam, the next step is to demonstrate that you can practically apply the concepts that you
have learned into real-world situations with real challenges and tangible benefits. This is done through
completion of one or two quality projects which are then reviewed and assessed by the certifying company.
If you pass all these steps, only then will you be conferred certification in the belt that you trained for.
There are many organizations in the US and around the world that offer Six Sigma training and certification.
This is both good and bad news for quality management professionals who want to be recognized as a Six
Sigma practitioner. On the one hand, it is good news because it’s not difficult to find an organization that will
offer to train and certify you for a fee. On the other hand, not all organizations are created equal; and so
many professionals make the mistake of picking a training and certification company that will train and
certify them for the sake of getting a certification.
Remember: Six Sigma is a complex, highly technical method consisting of a wide array of tools and an even
that requires expertise and sound knowledge of the relevant concepts. You can pick just about any training
and certification company but there’s a good chance you will not get the training and guidance that you
need to truly become an expert in Six Sigma.
This is where it becomes obvious that choosing the right training partner is paramount to your future success
as a quality management professional.
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How to Choose the Right Training Partner for Six Sigma Certification
For many professionals, it is tempting to overlook the process of selecting the right training partner for
getting a Six Sigma certification. There are a few reasons why this is becoming a trend nowadays.
First, many think that all training and certification partners are created equal and thus, there is little value in
putting some serious thought into selecting the right partner. “If Company A and Company B both offer Green
Belt certification courses, they will eventually end up teaching the same things, right?”
Simplilearn is a leading
provider of a suite of
professional certification
courses that address unique
learning needs of working
professionals.
Second, many seem to think that relying on your own skills and knowledge would be more than enough to
see you through the process. In this regard, many do not place premium on the guidance and experience of
training partners and how these matter tremendously in the overall scheme of things.“As quality management
professionals, we are often taught to rely on our skills to solve problems and demonstrate know-how in certain
fields. In getting a Six Sigma certificate, the same approach should also work, right?”
Third, and as a direct offshoot of reasons 1 and 2, selecting a training partner can be a time-consuming task
with no obvious benefit. “If I end up getting a certificate at the end of the process, why should I give time into
thinking where I need to get my training and certification, right?”
The truth is that as a result of this line of thinking, many end up taking certification courses from organizations
that are not suited to deliver the right material, support, and guidance that are essential for success. It bears
repeating that Six Sigma is a complex technical methodology that cannot be learned by simply sitting on a
desk. The manner in which the training and guidance is delivered matters towards how well you learn the Six
Sigma approach. This is important because as a quality management professional, you are expected to show
your knowledge and lead others.
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To select the right training partner, you need to spend some time assessing your options. Here are some of the
parameters to consider to narrow down your selections for the right training partner.
One of these accreditations is issued by the American Society for Quality (ASQ), a global community of
people dedicated to quality to ensure that professional training and certifications are conducted
according to global industry standards. The training material used by Simplilearn is also accredited by
PEOPLECERT Group, one of the most reputable global organizations in professional certification.
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Being recognized by global bodies like the ASQ is very important because it signifies that the
company is a respected leader in promoting professional training. When you invest for your training
and certification, the recognition and accreditation provided by the ASQ and other global
institutions assures you that your investment is not misplaced. This is one of the things that sets
Simplilearn apart from other organizations when it comes to conducting Six Sigma training and
guiding you through the certification process.
countries speaks to the versatility of the Simplilearn approach. In addition, more than 40% of
Simplilearn’s participants come from Fortune 500 companies, which speaks to the Simplilearn’s
reputation and recognition when it comes to Six Sigma training and certification.
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Training Continuation
Training Flexibility
Simplilearn also conducts face-to-face workshops globally to leverage its network of trainers. There
are currently about 300 workshops per month in different locations worldwide which widens its
availability and accessibility to professionals.
If, on the other hand, you prefer online trainings so you can match it to your schedule and availability,
Simplilearn also has a wide selection of e-courses that are available to professionals from all over the
world. The company currently has about 5,000 professionals accessing its e-learning system per
month, which is a testament to how accessible and available it is wherever you may be in the world.
You can also choose Instructor-led online courses which fuses the best attributes of classroom
trainings with the flexibility of online courses. This way, you still gain access to face-to-face instruction
by a qualified trainer while still doing it remotely and according to what your schedule allows.
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The key message here is to pick a training institution that offers considerable flexibility in how training
is administered. As a professional, you are undoubtedly busy with a lot of other things and you want
to be able to select the best time and location where you can get training without compromising the
quality of instruction.
Results
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The key message: You need to find an institution that mirrors the spirit of Six Sigma when it comes
to collaboration and mentorship. In any organization, you are expected to become a guide to those
who are less experienced than you as well as accept guidance from those who are more qualified.
What better way to practice this than during the project execution where you can collaborate with
certified trainers in order to learn the right approach and practice using the tools, as well as apply the
concepts with proper guidance.
There are many more factors that are crucial to selecting the right training partner when certifying for
Six Sigma. The process of comparing and contrasting programs may seem laborious but if done
correctly, it will significantly help you get more value out of the program. And in today’s business
world, there is no substitute for a training program that helps you create additional value and enhance
your career’s potential growth for the right price.
The actual time and effort it takes to complete a Six Sigma certification can vary from one training
partner to another and on the individual undergoing the certification.
Considering, however, that there are several complex concepts in Six Sigma combined with the need
to demonstrate adequate knowledge on the subject by passing the certification exam – and in some
cases, a personal project, the required time to complete the whole process can be substantial.
Below are estimated durations for each phase of the Six Sigma certification process.
The training portion will take about a few weeks in total. Classroom-based trainings are often
conducted over a 3-5 day period but continuous review of the concepts through online e-learning
resources takes an additional 3-5 weeks depending on the trainee. If you combine the period needed
to prepare for the exam, the whole training period can last up to 8 weeks.
The exam, depending on which organization administers it, is typically 3-4 hours in duration. We’ll
touch about the exam in more detail in the next section.
In cases where completion of a project is part of the certification requirements, the project execution
and completion can take anywhere from 8 to 16 weeks. Again, this is dependent on the trainee and is
highly influenced by the scope and complexity of the project. For green belt certification, the timeline
is definitely shorter. For black belt certification where a higher degree of understanding and
complexity is required, the whole certification period can be much longer.
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While there are no pre-requisites to getting a Six Sigma training – other than getting a Green Belt
certification before taking up a Black Belt training and certification course – it is favorable for quality
management professionals like you to already be familiar with the concepts of Six Sigma. A working
knowledge particularly on how to apply DMAIC methods in real-world situations will make it easier for
you to complete the Green Belt certification course.
If, however, you have no prior experience in Six Sigma, expect the process to require more time and
effort. The bulk of the extra time and effort required will mostly come from your individual study
sessions and in the e-learning courses and case studies provided by your training partner. If a person
with prior Six Sigma knowledge and experience is able to complete the Green Belt certification
process in 4-6 months, an inexperienced quality management professional will take almost double
that time before he or she can be confident and trained enough to pass the exam.
There is no single organization that administers the certification exam. In the US, the most popular certifying
bodies are the American Society for Quality (ASQ), and the International Association for Six Sigma Certification
(IASSC). Here’s what you can expect during the exam as it is currently administered by ASQ.
The ASQ exam for Green Belt certification consists of 100 total questions. To pass, you need to score
at least 70%.
Below is the condensed Green Belt Body of Knowledge outline as taken from the ASQ website with indications
on how the exam is split according to the number of questions pertaining to the D-M-A-I-C model.
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C. Design for Six Sigma (DFSS) in the organization
1. Quality function deployment (QFD)
2. Design and process failure mode and effects analysis (DFMEA & PFMEA)
3. Road maps for DFSS
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2. Six sigma and other team roles and responsibilities
3. Team tools
4. Communication
D. Probability distributions
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5. Short-term vs. long-term capability
6. Process capability for attributes data
B. Hypothesis testing
1. Basics
2. Tests for means, variances, and proportions
3. Paired-comparison tests
4. Single-factor analysis of variance (ANOVA)
5. Chi square
D. Control plan
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To look at a more detailed description of each of these areas, check the ASQ Exam Certification Guidelines at
http://asq.org/cert/six-sigma-green-belt/bok
The takeaway here is that the right training partner is invaluable to securing a Six Sigma certification. With the
extensive outline of topics where questions can potentially come, this underscores the importance of proper
training and coaching when getting a Six Sigma certification. Any training that is not geared towards mastery of
specific areas where questions can come from, will most likely lead to less than satisfactory exam results. In this
regard, it is worth remembering that Simplilearn has an excellent track record in helping quality management
professionals like you pass the certification process. Simplilearn has a 98.6% exam pass rate which puts emphasis
on its ability to point you to the right areas that need more focus and attention.
Simply put, you can never go wrong by trusting Simplilearn with your Six Sigma training and certification needs.
Choose the best for your Six Sigma training and certification needs.
Choose Simplilearn!
simplilearn
Accredited, approved and recognized as a training organization, partner, education provider and
examination center by globally renowned names like Project Management Institute of USA, APMG,
CFA Institute, GARP, ASTQB, IIBA and more
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Flexibility to choose across various modes: Classroom, Instructor-led online, and Online self-learning
Trusted by employees of Fortune 500 companies as their learning provider for career growth
and training.
Simplilearn follows a global learning framework proven to deliver results and has been perfected by
experience in training a million learners.
2000+ certified and experienced trainers conduct trainings for various courses across the globe.
24x7 live support via chat, mail and phone with a request to call back option
Interested?
Here is a sample Green Belt Certification Package from Simplilearn.
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At the end of Simplilearn’s training in Six Sigma Green Belt, participants will be able to:
Good Luck!