What is Six Sigma

Six Sigma is a system of statistical tools and techniques focused on

eliminating defects and reducing process variability.
The Six Sigma process includes measurement, improvement and
validation activities. The designation, or title, Six Sigma, relates to the
connection between the number of defects per million opportunities
and the number of standard deviations found within a process
specification.

Highly skilled personnel trained in the use of the statistical tools and
the techniques of Six Sigma implement the Six Sigma methodologies.
The Six Sigma training and certification levels are borrowed from the
martial arts. The certification or belt levels include white, yellow,
green, black and master black belt designations.
Master Black Belt
A Master Black Belt is classically trained in statistical tools, Six Sigma
methodology and management processes. Master Black Belts mentor
and direct groups of Black Belts and Six Sigma teams through various
problems that need to be reviewed.
Additionally, Master Black Belts are responsible for the strategy and
training of Black Belt level practitioners and below.

Black Belt
A Black Belt receives the highest level of training in the statistical
tools of Six Sigma.
Black Belts, as a rule, develop the plans for Six Sigma project
implementation.
Their responsibilities include creating project plans, leading cross-
functional projects and directing team members, including Green and
Yellow Belts. Black Belts usually train other team members on the
proper use of Six Sigma tools and techniques, such as control charts,
histograms and Root Cause Analysis (RCA).

Green Belt
Green Belts report to a Black Belt and lead process improvement
teams part time.
Approximately 25- 50% of their time should be devoted to working
on Six Sigma projects, usually within their own functional areas.
Green Belts receive training on DMAIC methodology, statistical tools,
proper data collection and analysis of the data collected.
Yellow Belt
A Yellow Belt should have a basic understanding of Six Sigma,
statistical tools and DMAIC methodology.
Yellow Belts are often members of the workforce recognized for their
skill, knowledge and experience with the process in question.
They often fulfill the role of Subject Matter Expert (SME) for the
process. They are valuable during the measure phase of a project,
gathering data, measurements and metrics.
However, Yellow Belts are not typically involved in the data analysis
process.
Six Sigma is more than a quality system, a set of statistical tools, a
certification system or a method for process improvement.
Some perceive it as a philosophy that embraces the belief that all
business processes are measurable and can be improved.

How to Implement Six Sigma

A typical Six Sigma project measures the current state and increases
the performance of the business process to a new and statistically
significant improved state using statistical tools. Standard Six Sigma
capability refers to a very small number of possible failures that can
exist outside the specification.
The method most frequently associated with Six Sigma is DMAIC,
which stands for Define, Measure, Analyze, Improve and Control.
Before beginning any Six Sigma improvement project, it is necessary
to select a process that, if improved, would result in reduced cost,
superior quality or increased efficiency.
The process also must possess measurable data because what you
cannot measure you cannot improve. The process selected may
currently be experiencing quality problems or generating a large
amount of scrap.
A Black Belt or Master Black Belt will usually initiate Six Sigma
projects through the creation of a charter.
The charter typically includes details of the proposed improvement
project, a business case and information regarding how the project fits
into the company’s goals or business strategy.
The following is a list of the project phases, along with a brief
description of each:

Define
The purpose of this step is to clearly articulate the business problem,
goal, potential resources, project scope and high-level project
timeline.
This information is typically captured within project charter document.

Measure
The purpose of this step is to objectively establish current baselines as
the basis for improvement; this is a data collection step, the purpose
of which is to establish process performance baselines.

Analyze
The purpose of this step is to identify, validate and select root cause
for elimination.

Improve
The purpose of this step is to identify, test and implement a solution to
the problem; in part or in whole.

Control
The purpose of this step is to embed the changes and ensure
sustainability, this is sometimes referred to as making the change
'stick'.

Control is the final stage within the DMAIC improvement method.

Six Sigma
Six Sigma is the original process improvement methodology.

It was first used by Motorola in manufacturing.

Since then, it’s use has spread to almost every industry.

Continuous process improvement is a universal need

Lean
Like Six Sigma, Lean focuses on process improvement.

It was first used by TOYOTA in manufacturing.

However, Lean focuses on attacking waste.

Lean Six Sigma

Here we have the hybrid methodology that combines the best of both
Lean and Six Sigma. Organizations began turning to this idea when
they realized they had issues in areas the separate approaches handle.

Essentially, those who use Lean Six Sigma seek to eliminate waste in
ways defined by Lean while also seeking to improve processes by
putting DMAIC and DMADV in place.
Combined, the two methodologies help companies become more
efficient across all operations while also creating better quality
products and services.

The right one to choose depends on the needs of an organization.

But the above outlines where and how the three methodologies are
used. Despite the differences, they are all designed to increase a
company’s competitive advantage.

Those with knowledge in Lean, Six Sigma and Lean Six Sigma are in
position to take a lead role in implementing needed changes.

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