What is Six Sigma ?
Six Sigma is a method that provides organizations tools to improve the capability of their business processes. This increase in performance and decrease in process variation helps lead to defect reduction and improvement in profits, employee morale, and quality of products or services.
Six Sigma focuses on reducing process variation and enhancing process control, whereas lean drives out waste (non-value added processes and procedures) and promotes work standardization and flow. The distinction between Six Sigma and LEAN has blurred, with the term “lean Six Sigma” being used more and more often because process improvement requires aspects of both approaches to attain positive results.
Lean Six Sigma is a fact-based, data-driven philosophy of improvement that values defect prevention over defect detection. It drives customer satisfaction and bottom-line results by reducing variation, waste, and cycle time, while promoting the use of work standardization and flow, thereby creating a competitive advantage. It applies anywhere variation and waste exist, and every employee should be involved.
Define the problem, improvement activity, opportunity for improvement, the project goals, and customer (internal and external) requirements.
- Project charter to define the focus, scope, direction, and motivation for the improvement team
- VOC to understand feedback from current and future customers indicating offerings that satisfy, delight, and dissatisfy them
Measure process performance.
- Process map for recording the activities performed as part of a process
- Capability Analysis to assess the ability of a process to meet specifications
- Control Charts to assess process is stable or not.
- Pareto Chart to analyze the frequency of problems or causes
Analyze the process to determine root causes of variation and poor performance (defects).
- Generating causes through Brainstorming Technique
- Cause Validation and Verification
- (RCA) to uncover causes
- (FMEA) for identifying possible product, service, and process failures
Improve process performance by addressing and eliminating the root causes.
- Generating Solutions through Brainstorming Technique to overcome significant root causes.
- Solution Prioritization with respect to ease of implementation, risk, investment.
- (DOE) to solve problems from complex processes or systems where there are many factors influencing the outcome and where it is impossible to isolate one factor or variable from the others
Control the improved process and future process performance.
- Control Plan to document what is needed to keep an improved process at its current level
- (SPC) for monitoring process behavior
- 5S to create a workplace suited for visual control
- (poka-yoke) to make errors impossible or immediately detectable
Our Six Sigma Process ?
Lean Six Sigma Process:
- Sr. Leadership (Champion) Awareness Program on “Business Excellence Through Six Sigma
- Top Management Expectation alignment
- Creating Project Bank through Proactive and Reactive Approach.
- Prioritizing the Projects
- Team Formation
- Establishing structure and various policies and mechanism for Project Communication & Promotion, Monitoring & Review, Change Management,
- Phase Wise Training
- Coaching and mentoring for deployment
- Toll gate review after each phase completion
- Final Review, Success Story, & Celebration.
- Reward and Recognition, Sustenance plan and horizontal deployment.
Benefits of Six Sigma ?
- The financial benefits of Lean Six Sigma are large in a way that increases profits by reducing cost, and benefits from an increase in revenue.
- Improved business processes for Efficiency, Productivity, Quality, Delivery, Inventory, Cost, EHS & morale.
- Improved Employee Satisfaction and Enhancing Improvement Culture.
- Improved Customer Satisfaction.