Author Archives: Six Sigma Expert

Six Sigma Softwares

Basically there are three classes of software used for the implementation of Six Sigma methodology.

(1) Analysis tools: They are used to perform statistical or process analysis. Six Sigma methodology applies the advanced statistical solutions to the complex problems for process improvement and these tools make life easier for the professionals.

Some of the widely used tools are as follows

(a) Microsoft Visio: It is a Microsoft Windows program that is diagramming in nature and uses vector graphics for the creation of diagrams. It comes in two editions: Standard and Professional. They have templates for advanced diagrams and layouts and possess unique functionality which helps users to connect their diagrams to a number of data sources in addition to displaying the information graphically.

(b) Minitab is basically a statistics package used as an analysis tool distributed by Minitab Inc. It is often used in along with Six Sigma implementation, CMMI and other statistics-based process improvement methods. Minitab 15 is the latest version which is available in 6 different languages (English, French, German, Korean, Simplified Chinese, & Spanish).

(c) STATISTICA : It is is a statistics and analytics software package which provides a selection of data analysis, data visualization, data management, and data mining procedures. It is developed by StatSoft.

Other famous analysis tools which are commonly used are iGrafx process, IBM websphere Buiness Modeler, JMP, SigmaXL, Statgraphics,Telelogic System Architect, etc.

(2) Program management tools : They are the set of tool which are used to manage and track a the entire Six Sigma program of a corporation.

(3) DMAIC and Lean online project collaboration tools: These are the softwares which assist in implementation of Six Sigma across local and global teams. They help in effective management of the projects. One very famous Example is Grouputer Sigmasense.

Advantages and Disadvantages of Six Sigma

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Six Sigma as a path breaking methodology for the business improvement has its own advantages and disadvantages.

Advantages :

(1) Six Sigma is driven by the customer and thus aims to achieve maximum customer satisfaction and minimizing the defects. It targets the customer delight and new innovative ways to exceed the customer expectations.

(2) Implementation of Six Sigma methodology leads to rise of profitability and reduction in costs. Thus improvements achieved are directly related to financial results.

(3) Six Sigma is successfully implemented in virtually every business category including return on sales, return on investment, employment growth and stock value growth.

(4) Six Sigma targets Variation in the processes and focuses on the process improvement rather than final outcome.

(5) Six Sigma is prospective methodology as compared to other quality programs as it focuses on prevention on defects rather than fixing it.

(6) It is attentive to the entire business processes and training is integral to the management system where the top down approach ensures that every good thing is capitalized and every bad thing is quickly removed.

Disadvantages

(1) Applicability of Six Sigma is being argued among the Six Sigma critics. They opined that the quality standards should be according to specific task and measuring 3.4 defects per million as standard leads to more time spent in areas which are less profitable.

(2) Six Sigma gives emphasis on the rigidity of the process which basically contradicts the innovation and kills the creativity. The innovative approach implies deviations in production, the redundancy, the unusual solutions, insufficient study which are opposite to Six Sigma principles.

(3) People argue that Six Sigma is a bit gimmicky and simply a rebranding of the continues improvement techniques and tools as practiced by Toyota. It thus promotes outsourcing of improvement projects with lack of accountability.

(4) Six Sigma implementation constantly require skilled man force. Thus control and employee dedication are hard to accomplish if its not implemented regularly.

(5) While converting the theoretical concepts into practical applications there are lot to real time barriers which needs to be resolved.

Jobs and Career Options in Six Sigma

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Six Sigma jobs are available at all the levels in both at junior and senior level in different companies. These jobs have varied job descriptions and requirements which are unique to each organization

The Job Titles of Six Sigma professional usually vary depending on the requirements of the organization. Basically these titles suggest more or less to the skills of a Six Sigma professional that are certified as Black Belt.

Professionals meeting these requirements are expected to have required training in Six Sigma methodologies and practical experience in handling cross-functional process improvement projects and teams.

Openings for senior level Six Sigma jobs usually requires individuals who have been certified as Master Black Belts. These professionals are experts in the various methodologies of Six Sigma and responsible for the execution of Six Sigma methodology across organization. This opening probably demands the highly qualified professional with rich experience of handling Six Sigma projects.

Various Job Titles given to the Six Sigma Professional are as follows :

Six Sigma Methodology Trainer, Green Belt, Black Belt, Master Black Belt, Yellow Belt Trainer

Certification Trainer, Quality Improvement Trainer, Designer for six sigma, Project Program Manager

Senior Business Analysis Consultant, Vice President of Lean Delivery/Business Developer

Process Consultants, Quality Director, Director, Business Process, Lean Six Sigma Black Belt

Master Change Facilitator, Six Sigma Master Black Belt, Six Sigma Black Belt-Sales

Director of six sigma, Process Engineer/Consultant, Seed Manufacturing Research Statistician

Six Sigma Quality Manager, Lean Black Belt, Wind Field Product Quality, Manager Operational Excellence

Six Sigma Black Belt, Process Engineer- six sigma, Six Sigma Master-Manufacturing Engineer

Project Leader- Process Excellence, Six sigma black belt- Quality Assurance Engineer

Project Manager, Plant Manager, Senior Process Engineer/Consultant,

Experienced Kaizen Leader/ Lean Six Sigma Expert, Senior Quality Engineer, Design for Six Sigma Manager

Six Sigma As a Career

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The demand for Six Sigma professionals has increased manifold in recent times and there is huge requirement for experienced Six Sigma professionals such as a Six Sigma Green Belt , a Six Sigma Black Belt , a Master Black Belt, and a Champion. Qualified Six Sigma professionals who have a rich experience may start their own consultancy business.

Many organizations have become aware that by implementation the Six Sigma methodologies, hige benefits can be derived. New concepts related to Sic Sigma have been developed which can be applied to the services as well as governmental organizations. This has created the requirement of lots of Six Sigma professionals.

Nowadays even small sized companies are also implementing the Six Sigma methodologies for improving their quality and cutting costs. These organizations provide bright opportunities for Six Sigma professionals by hiring them as consultants or permanent employees.

Job opportunities are available both within the organization as well as outside the organization.

Opportunities within the organization

Companies which are planning to implement Six Sigma in their organization uaually prefer to provide six-sigma training to its current employees. This helps in reducing the costs associated with hiring Six Sigma professionals from outside who are expensive. Providing training to existing employees is also beneficial as they are aware of the company’s business processes and will be more effective in executing the implementations.

After the completion of the training, employees are entitled to receive the certifications. They can implement their training in the practical hand on experience and thus add value to their resumes and greatly enhances their career prospects.

Opportunities outside the organization

There has been increase in the Six Sigma job opportunities and qualified professionals can apply for jobs which is best suited to their job profile. Depending on the scenario. Companies may hire both the fresh candidates as well as experienced candidates, however demand will be more for the candidates having two years of implementation experience.

To excel in their jobs, Six Sigma professionals are required to display creative and problem-solving abilities. Good communication and inter-personal skills are also mandatory.

Six Sigma Case Studies

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Case Study is defined as research strategy, which investigates the phenomenon with in real life scenario. It may include single and multiple case studies. It involves quantitative and qualitative evidence relying on multiple sources and benefits from prior developments.

Six Sigma case study talks about building up of the framework, related to the implementation of Six Sigma methodology in the minds of the organizations. Case studies are developed basically on the benefits of Six Sigma methodology leading to growth and improvement of organization and a project.

Case studies are made on wide range of fields across the business and industrial sector like IT, call centers, large companies based in the US and India etc. This case study provides useful insight into the areas where Six Sigma is being applied and what aspects of Six Sigma is more effective and adopted by the organizations for their success in terms of quality, performance and cost reduction.

Case studies reveal that DMAIC is more frequently used Six Sigma methodology. Some of the key aspects in which the help of Six Sigma is used for developing the case studies made are as follows:

(1) Identifying the problems and their root cause

(2) Identifying the defects of the products

(3) Formulation of ideas to avoid the defects

(4) Idea testing and modifications

(5) Implementing the modified products

(6) Confirming and monitoring the product results

(7) Tracking the improvement and the customer satisfaction

(8) Focusing on Long term quality improvement

(9) Inculcating the six sigma techniques and mind-set

Adopting a Business Process Approach to Management requires various critical steps by the organizations. Case study reveals that critical steps required for the successful implementation of DMAIC are determining the Customers and Stakeholders and benefits organization is providing them, determining the value chain that deliver benefits, identifying process boundaries, selecting the process owner for each process, beginning of never ending cycle Business Process Improvement, etc.

Examples of Six Sigma Case Studies

Application of Six Sigma DMAIC methodology has resulted in vast improvement in the performance of organization as evident by the numerous success stories across the globe. Some examples of the case studies are as follows.

(1) Oil exploration and drilling company. Project was to Improve automatic well test process. Results : Increase in test accuracy by 25% and Improvement in % of successful “workovers”.

(2) Vehicle maintenance support unit . Project was reduction of the high cost of vehicle maintenance. Results : Moving technical experts to the field and Improved data collection techniques

(3) Large Electronics Company. Project was to Deflect yoke for TV. Results : Upgradation of the design using DFSS tools and improvement in overall production process

(4) Automotive Project was failures of Crankshaft production Results : Application of Six Sigma tools to stratify the errors which were due to grinding failures.

(5) Pharmaceutical Company. Project was Packaging- downtime of machines on the packing line was excessive leading to lower than expected productivity Results : SOPs were developed, improvement in Training and Variation in the adjustments and reduction of adjustment frequencies.

(6) Chemical Production Project was to improve production capacity and reduce variability of Methyl Ethyl Ketone (MEK) and Ethanol Separation Unit. Results : improvement of Normal production rates for MEK and Ethanol by more than 4% above previous maximum rate and decrease in Ethanol losses.

(7) Transactional Project was reduction in Employee productivity when employees transfer to different jobs within the company. Results : Lost productivity resulted because of failure of direct deposits, interrupted health care, increase in out-of-pocket expenses, etc. DMAIC process leading to improved process flows.

(8) Medical Device Company Project was Combining the two existing rejection systems used for tracking defective materials. Results : The two systems were combined, streamlined, and placed on the web and creation of Process flow for new process

Best Institutes for Six Sigma Certification

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There are lots of training institutes and consultants who provide the certifications on completion of their course. Some of the famous certifications are from ASQ, IEE, BMG, and Benchmark Six Sigma.

ASQ : The American Society for Quality (ASQ) is one of the primary professional organization who provides Six Sigma Certifications. It is most widely recognized internationally and best known for their level of professional certifications. They are offering two courses – Green Belts certification and Black Belt certification. Soon they will offer Certified Six Sigma Master Black Belt in the future. They have huge collection of resources including articles, books etc.

In India, Federation of Indian Chambers of Commerce and Industry (FICCI) has a tie-up with ASQ.

IEE : The Institute of industrial engineers is the leading provider of the cutting edge eduction and is recognized internationally. The certificate programs are available as corporate training program which can be customized as per the company focus. They offer wide range of courses including Lean Six Sigma Green Belt, Six Sigma Black Belt , Six Sigma Green Belt Certificate.

BMG : Breakthrough Management Group specializes in Lean, Six Sigma, Process Management and innovation and is leading provider of consulting and training to provide excellence in performance. It provides over 35 courses in the areas of performance excellence such as Lean, Six Sigma etc.

Benchmark Six Sigma is one of the leading provider of certification and training offering business excellence knowledge across industries. They offer Six Sigma Champion training, Master Black Belt Certification, Black Belt Certification and Green Belt Certification.

International Quality Federation (IQF) is renowned professional organization that offers an certification exam in Six Sigma.

Usually Six Sigma black belt certification needs 3+ years of work experience along with two completed projects and Green Belt certification requires 3 years of work experience.

Failure Mode and Effects Analysis

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A failure modes and effects analysis (FMEA) is a process of analysis of potential failure modes within a system. It is based on the determination of severity and the effect of failures on the system. It is widely used during the various phases of the product life cycle in manufacturing industries and is getting popular in the service industry.

Failure modes are any defects in a process, design, or item, especially those that affect the customer. It can be potential or actual. The consequences of those failure modes are studied under effect analysis.

Usage of FMEA is done in the development of system requirements which minimize the occurrences of failures, in development methods for design and test system ensuring elimination of failures and in evaluation of the needs of the customer ensuring it does not give rise to potential failures.

Pareto chart

A Pareto chart is a special type of bar chart which depicts the values being plotted in thegraph are arranged in descending order. The graph is accompanied by a line graph showing the cumulative totals of each category from left to right. The chart was resulted due to the work of Vilfredo Pareto who concluded that 20% people controlled 80% of wealth leading to rise of Pareto Effect.

The Pareto effect also operates in area of quality improvement as well and suggests that 80% of problems usually stem from 20% of the causes. They are used for displaying the application of the Pareto principle in action.

Project Charters

A project charter is the first step in the implementation of Six Sigma methodology. It is applied in the Define step of DMAIC and the charter is highly responsible for the success of the project. Necessary Project Charter Areas are Project Title, Black Belt/Green Belt, Mentor/Master Black Belt, Project Start Date, Anticipated Project End Date, Cost of Poor Quality.

SIPOC Diagram

SIPOC is a six sigma tool which stands for Suppliers, inputs, process, outputs, customers. Supplies provides the inputs, value is added through our process and output is provided meeting or exceeding the customer’s requirements.

It is a tool used by a team for the identification of all relevant elements of a process improvement project before the beginning of the work. It helps in defining a complex project that may not be well scoped, and is typically applied the Measure phase of the Six Sigma DMAIC methodology.

It is useful in determining inputs to the process, who are the customers and what are their requirement.

Root cause analysis

Root cause analysis (RCA) is a class of problem Solving methods directed at the identification of root causes of problems. It is based on the belief that best way of solving the problems is to eliminate root causes as compared to address the immediately obvious symptoms

It is a reactive method of problem detection and solving initially which means that the analysis is done after the occurrence of an event. Later on it becomes a pro-active method which suggests that it is able to forecast the possibility of an event before its occurrence.

Histogram

A histogram is a specialized bar chart which graphically summarize and display the distribution of a data set related to the process. It displays individual data points grouped together in classes. It helps to get an idea of how frequently data in each class occur in the data set.

High bars suggests more points while low bars indicate less points in a class. Histograms and control charts needs to be reviewed for consecutive process running over an extended time to obtain useful knowledge about a process.

It helps in finding the most common system response, type of distribution data , whether data is symmetric or it contains outliers.

Six Sigma Projects

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What is Six Sigma Project

Strategic planning of the projects plays a major role in the success of the company. In order to fulfill the requirements of the clients, company assigned the work called as projects to its professionals. Effective communication, proper planning and execution of strategy into actions are imperative for the successful implementation of the project.

Six sigma focuses on one project at a time. To have a project-specific vision right from the very beginning of a Six Sigma initiative is not always possible however one can develop a comprehensive viewpoint which encompasses everything and helps to reach out beyond the scope of the project.

The effectiveness of the properly selecting and defining business issues is proven by the success stories of companies who have saved billions of dollars. For the effective solution the properly selected and defined business issues can be assigned to Green Belts and Black Belts. Six sigma projects provides the ideal way for the accomplishment of company’s strategic goals.

The evaluation and formalization of the issues is being done with the help of project charters. It allow the professionals to prioritize for the implementation of Six Sigma projects. In following the Six Sigma methodology through the define steps of DMAIC, this is the first step being developed. The success of a project relies heavily on the project charters. It specify the necessary resources and boundaries leading to success.

Project Selection

A Six Sigma Project should have easily identifiable process inputs and outputs. Care has to taken while selecting the Six Sigma projects and it should not rely on predetermined solution as a remedy for the issues. The benefits and drawbacks of the project should be considered before selecting the project.

Apart from the monetary aspect, approach should involve the understanding the variation in process inputs, controlling them, and eliminating the defects. Effective implementation of a Six Sigma project involves sub-dividing the project deployment in two or three phases which can be strategic, tactical and operational.

Project Selection Ideas

Six Sigma follows the project selection ideas as per the function. Some of the ideas of project selections based on the functional areas are as follows:

(1) Finance/ Accounting six sigma project ideas

(2) Human Resources six sigma project ideas

(3) Sales six sigma project ideas

(4) Shipping or Receiving six sigma project ideas

(5) Information Technology

(6) Product or Service Design six sigma project ideas

(7) Call Center six sigma project ideas

Deployment Strategy

After the identification of the project, the project deployment strategy should be contemplated keeping in mind the background of both the top and bottom line developments. Before beginning the implementation, the projected outcome should be compared as against the set management goals.

The strategic steps involved in all phases should scrutinize using the checklist in place. Executing a draft strategy and taking the collective opinion for the foundation of the project is imperative in the moving ahead in correct direction.

In cases where the project deviates from its track and if it remains undetected, then it can pose a big threat to the entire project. To prevent these occurrences, the internal and external Six Sigma auditing team should ensure that there is regular midway auditing and monitoring.

Problem and its possible causes needs to be identified at the earliest. Regular Monitoring is imperative to avoid progress in undesirable directions.

The framework for effective communication for the “belts” should be established. To effectively implement the strategies of deployment team, a core group should be created. Consistent training needs to be provided to the Six Sigma team members.

Survey of the internal customers need to be carried out and findings should be studied. All projects should involve the focus on eliminating the defects, identifying the variation in process inputs and taking effective measures in controlling them.

Six Sigma Yellow Belt

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A Yellow Belt possess basic knowledge regarding the tools and methodologies of Six Sigma.They do not lead the projects on their own unlike Green Belt and Black Belt. They may be referred to as Green Belts depending from business to business. They support the Six Sigma projects by developing the process maps.

Yellow Belt possess the in depth knowledge and thus act as the subject matter expert on the projects and forming the core team members. Yellow belt are responsible for integrating the lean and six sigma methodologies in order to achieve the high level production and transactional systems leading to customer satisfaction. They usuall y carry out the smaller process improvement projects by following the PDCA methodology which helps them to identify the processes that could benefit.

Certification of Yellow Belt provides the thorough understanding of the processes and thus enables each individual to provide meaningful assistance for the achievement of the organizations overall objectives.

Lean Six Sigma Certification

Lean six sigma certification provides the professionals with the process improvement methodologies of Six Sigma and practices of Lean tools. Lean certification equipped the professionals in achieving the skills required to contribute to process improvement projects.

Typically a lean Six Sigma Certification focuses on the following

(1) Focusing on enterprise resource management and improvement.

(2) In depth understanding of integrated Lean Six Sigma business process management methodology for process improvement.

(3) Using advanced statistical tools and software to analyze the data

(4) Mapping and modeling the organization processes for practical analysis including value streams and process flows.

(5) Learns to identify the potential areas, deciding on the improvements, meeting the customer expectation and the business goals.

(6) Identifying and eliminating the non value added activities related to process design and product flow.

(7) To ensure the improvements are sustained, emphasis is given on chasing the variations and waste out of the system.

Degrees of Six Sigma Certification

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Companies provides the Six Sigma training to its professional based on their rank in the organization. There are various level of professional Six Sigma Employees and these levels resembles the same lines of Martial Arts Belts. In order to get to the higher level, further training is required. The color of the belt points to the level of the course achieved by a professional.

Six Sigma Green Belt

The first or lowest level of belt is Green Belt and it represent the employee of the company who has been trained on Six Sigma improvement methodology and as a part of their full time job, lead quality improvement team.

They possess less Skills and knowledge related to Six Sigma as compared to the Black Belt or Master Black Belt. They are responsible for the implementation of Six Sigma at an organization level. They assist the Black Belts and carried out their directions in execution of the projects. They lead the improvement projects within their respective areas. Usually the number of Green Belts exceeds the Black Belts in an organization.

Six Sigma Black Belt

Next level is Black Belt and they are responsible for the successful implementation of the projects using the Six Sigma methodology (DMAIC or DFSS) within the organization. They take two weeks of specialized training in addition to the training imparted to the Green Belts.

They are the Six Sigma Team Leaders who are experts in the Six Sigma tools and methodologies. They have detailed knowledge of the roadmaps, cross functional process improvement, and extensive arithmetical methodologies. They ensure that tools used lead to increment in business production and Customer Satisfaction.

Additionally Black Belts also coach and mentor other Green Belts and take guidance from Master Black Belts.

Six Sigma Master Black Belt

Master Black Belts are at the top level of Belt. They are experts in Six Sigma Quality Integration and executes the successful strategic implementation within an organization. Their responsibilities include coaching and mentoring of Black Belts and Green Belts, helping to prioritize, design, select and execute high-impact projects; maintaining the integrity of the Six Sigma measurements and developing and revising training materials of Six Sigma.

They are highly trained Six Sigma Black Belts and provides training to lower Six Sigma facilitators related to the methodologies, tools, and applications of Six Sigma and helps them in achieving their certifications.