Introduction to Lean Six Sigma

Learning Outline • • • • What is Six Sigma • Why DMAIC is different from other Quality The Six Sigma Philosophy Models Brief History of Six Sigma • Six Sigma Certifications DMAIC Methodology • Six Sigma Roles – Define • Recap – Measure – Analyze – Improve – Control 2 .

999.4 hours! 3 .000.4 in 1.000.996 parcels on time while approx only 4 (3.000 parcels a courier company delivers apprx.000.4) are delayed ! Out of 1.000 service hours a telecom company’s service are up 999.What is Six Sigma (6σ) Six Sigma (6σ) represents the level of quality when the defects are decreased to 3.000 million opportunities Few Examples Out of 1.996 hours while experiencing the down time of only 3.

000.e.000.What is Six Sigma (6σ) • • • Have you noticed the large sample size – i.000. 1.000 ? What if we don’t have 1.000 Opportunities 150 Opportunities 4 .its just a ratio between opportunities and defects 1.000 opportunities .000 samples / opportunities …… well lets run few quick tests Its Not necessary to have 1.000 Opportunities 25.000.

Six Sigma Philosophy The quality of the product /service depends on the process used to develop that product/service Six Sigma :  Improves the underlying business process  Is Customer focused  Uses statistical tools 5 .

general Electric and Allied Signals were the early adapter of Six Sigma 6 .Brief History of Six Sigma Bill Smith in 1986 standardized Bill Cohen – an the Six Sigma engineer in i. 1 Mil Motorola Opportunities coined the term In 1818 Six Sigma for Johann Carl the firs time Gaussian introduces concept of Normal Distribution – Motorola reported $ 16 Billion savings due the basis of to Six Sigma Adoption Six Sigma Motorola .e. Citibank .

DMAIC Methodology DMAIC is abbreviation of the 5 key steps required to run Six Sigma projects Define Control Measure DMAIC Improve Analyze 7 .

Define Phase – Steps & Tools Develop Charter and Business Case SIPOC Process Mapping Map Existing Processes Value Stream Mapping Define Spaghetti Chart VOC Collect Voice of Customer Affinity Diagram Specify CTQ Requirements CTQ Tree Step Tools 8 .

Measure Phase – Steps & Tools Measure CTQs CTQ Tree Determine Process Stability Statistical Process Control Data collection Check Sheet Measure Data & Data Collection Validate Measurement System R& R gauge Calculating Cp & Cpk Establish Process Capability Step Tools Histogram 9 .

Analyze Phase – Steps & Tools 5-Whys Identify Root Causes Fishbone Diagram Analyze Quantify Root Causes FMEA Tools Scatter Plot Verify Root Causes Step Tools Correlation and Regressions Analysis 10 .

Improve Phase – Steps & Tools Generate and Select Solutions Brainstorming Cost-Benefit Analysis Deign Solutions Improve Prioritize and Select Solutions Pilot Solutions Implementing Solutions Step Tools ROI A3 Report 11 .

Control Phase – Steps & Tools Develop Control Plan Apply Statistical Process Control Develop Control Transfer Required Tools to Process Owners Perform Financial Evaluation and Audit Step Tools 12 .

How is DMAIC Different Cohesive Process Based Quantitative Project Based Stakeholder improvement Comprehensive DMAIC Customer Centric 13 .

Six Sigma Certification MASTER BLACK BELT BLACK BELT GREEN BELT YELLOW BELT WHITE BELT 14 .

Six Sigma Roles Executive Management / Sponsors MASTER BLACK BELT BLACK BELT GREEN BELT YELLOW BELT WHITE BELT 15 .

Recap Six Sigma :  Improves the underlying business process  Is Customer focused  Uses statistical tools DMAIC is Six Sigma Methodology with following phases :  Define  Measure  Analyze  Improve  Control 16 .

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