Six Sigma is actually a set of statistical techniques and tools for process improvement, which is a system implemented with the aim of reducing the possibility of defects and improving processes.
That group of statistical techniques and tools – 6 is an abbreviation for standard deviations. Mathematically a Six Sigma process means 2 defects per billion opportunities. Which can be considered an almost zero-defect process.
In a manufacturing environment, however, the ideal target for process efficiency is 3.4 defects per million, which is almost negligible in number and is considered a near-zero defect process. The most prominent of 6 sigma‘s strategies is to identify the causes of defects and reduce variability in manufacturing and business processes, thereby improving the quality of production processes.
From the point of view of Six Sigma definitions
Sigma
A term used in statistics that measures the standard deviation. In business, it is an indication of defects in the outputs of a process and how far these outputs are from perfection.
Six Sigma
A statistical concept that measures a process in terms of defects. At the Six Sigma level, there are only 3.4 defects per million opportunities. Six Sigma is also a management philosophy that focuses on eliminating defects through practices that emphasize understanding, measuring, and improving processes.
Why is 6 Sigma (Six Sigma) called 6 Sigma?
Because it is a statistical or mathematical average of a process data set, performance is measured based on the standard deviation of the DPMO (Defects per Million Opportunities). The greater number of standard deviations of the mean should fit between the process mean and the acceptable process limits. If the process performs beyond the acceptable process limits, it causes a defect. Obviously, the 6σ process outperforms the 1σ, 2σ, 3σ, 4σ, 5σ processes. Friends below is the standard deviation table for Six Sigma, which will give you an idea of how much improvement you need on the processes in your production areas.
Sigma Level | DPMO (Defects per Million Opportunities)
| SPECIFIC LIMIT | PERCENT | DEFECTIVE PPM |
|---|---|---|
| ± 1σ | 30.23 | 697700 |
| ± 2σ | 69.13 | 308700 |
| ± 3σ | 93.32 | 66810 |
| ± 4σ | 99.37990 | 6210 |
| ± 5σ | 99.97670 | 233 |
| ± 5σ | 99.99966 | 6.4 |
It is clear that as the level of sigma processes increases, the results of the processes get better. Primarily Six Sigma’s processes are considered better using a set of quality management methods based on experiences, and statistical methods. Each Six Sigma project follows a defined sequence of steps performed within an organization and has specific value goals.
For example:
- Reduce process cycle time
- Reduce pollution
- Cutting costs
- Enhance customer satisfaction
- Profit maximization
DMAIC Methodology in Six Sigma
In fact, DMAIC is a term coined from the first letter of the five steps, that word (Define, Measure, Analyze, Improve, and Control).
There are five steps in the DMAIC method:
Define
As part of this methodology, you will need to define the voice of the customer and their needs, and specifically the goals of the project. Clearly define the process goals on the project goals in terms of meaning critical to quality or critical to production.
Measure
The main objective of this step focuses on collecting relevant data and identifying the parameters that need to be quantified. These include measuring key aspects of the current process and collecting relevant data, methods for measuring them, and calculating process efficiencies.
Analyze
The main objective of this step is to analyze the current scenario in terms of the reasons for the variations and defects. in which:
- Process weakness analysis
- Sources of blame
- Investigation of cause-and-effect relationships
- Determine relationships.
- Making sure all factors are consider.
Improve
This step aims at improving the current process based on the analysis of all the collected data. The focus should be on process improvement by systematically reducing variation and eliminating defects.
Control
The main purpose of this step is to control the future performance of the process. Continuously monitor all those processes from the control system to make them standard procedures.
This methodology’s first scenario should focus on significant process improvements. The DMAIC method is employ in situations in which a product or process already exists. But is not meeting the customer’s specifications.
What is the difference between 6 sigma and lean manufacturing?
Six Sigma and lean manufacturing are toolkit for reducing waste in business processes. Both six sigma and lean manufacturing are proven concepts and have saved customers millions of dollars without capital investment. The Six Sigma system helps your associates generate business results. The return on investment provided by our approach is over 700%!
Six Sigma
This is actually, methods integrate business, statistics, and engineering principles to achieve tangible results. The tools are use to improve the processes and products of a company. They apply to every discipline including production, sales, marketing, design, administration, and service.
Six Sigma provides a wealth of tangible benefits. When skilfully implemented by its people:
- Six Sigma reduces costs by 50% or more through a self-funded approach to improvement.
- Six Sigma reduces the waste chain.
- Six Sigma produces a better understanding of customer requirements.
- Six Sigma improves the performance of delivery and quality.
- Provides critical process inputs needed to deliver Six Sigma feedback. changing customer requirements.
- Six Sigma develops robust products and processes.
- Six Sigma drives rapid improvement with internal resources.
Lean manufacturing
Lean manufacturing is a proven approach to reducing waste and streamlining operations. The Lean manufacturing embraces the philosophy of continually increasing the proportion of value-added activity of your business through continuous waste elimination. A lean manufacturing approach provides the tools to survive in a global market that demands high quality, fast delivery, and low prices. especially:
- Lean dramatically reduces the waste chain.
- The manufacturing reduces inventory and floor space requirements.
- It is creates a more robust production system.
- The Lean manufacturing develops appropriate material distribution systems.
- A lean manufacturing improves layout for increased flexibility.
Efficient logistics operations play an increasingly important role in many organizations. The rigor, discipline and tools provided through key program can help establish a state-of-the-art logistics operation. Six Sigma Systems provides a Initial program for logistics applications.
It is adapt to the particulars of supply chain management and the tools taught in our Prime Logistics program incorporate the analytical methods found in traditional 6 Sigma programs to ensure a successful implementation. We also use our development experts to develop tools and models to fit your industry conditions and constraints.