Question1: 

 Why it is Six Sigma and not Five or Seven Sigma?

Answer:  The number Six represents the standard deviations between the mean of a
process and the closest specification limit. If a process is been carried out under
these deviation then at maximum there will be only 3.4 defects per million
opportunities (including the 1.5σ shift, otherwise its ≈2 defects per million). Beyond
these standard deviations, the specification Criteria will not be met and the Sigma
value (Z score) will be negative.

Question2:  What are the methodologies used in Six Sigma?

Answer: DMAIC, DMADV and DFSS other Quality Management tools used are
Critical-To-Quality Tree, the Process Map, Histogram, Pareto Chart, Process
Summary Worksheet, Cause – Effect Diagram, Chi Squared Diagram, Scatter
Diagram, Run Chart, and Control Chart

DMAIC

Define: Involves collating requirements from the client and defining an objective for a
project.

Measure: Encompasses comprehension of crucial features of the process involved,

its prospective scope and relevant data collection.

Analyze: At this stage, data analysis is done to evaluate the defects, their root
causes and the effects on the process.

Improve: Required changes are done in the current process to mitigate the causes of
defects and to verify & enhance its capability.

Control: This stage focuses on controlling the future process with the solutions
analyzed earlier so as to ensure that any deviation in the future can be rectified
before causing the defect.

DMADV

Define: It involves outlining goals in accordance with the organizational strategy or

client requirements
Measure: At this stage, crucial elements are recognized by methods like Critical – To
– Quality along with identification of process capability and mitigation of risks
involved

Analyze: Solutions are analyzed and implemented to meet client requirement

Design: An optimum solution design is selected and applied to the process

Verify: New pilot projects are run to evaluate the efficiency of the process and then
the process is then delivered to the client

DFSS

Design for Six Sigma is a method to enhance the capability of a new process that
fulfils customer requirements to the best.

 Quality Management tools are utilized by DMAIC & DMADV/DFSS methodology or

even outside Six Sigma to augment quality along with risk mitigation.

Question 4: What’s the difference between Lean and Six Sigma?

Answer:  Lean Approach and Six Sigma basically aim for the same objectives — to
enhance the process involved. The Lean approach on the one hand is basically
applied to production and manufacturing processes while Six Sigma has a wider
implementation circle that includes service processes as well. The most significant
difference between the two is — Lean focuses on eliminating unnecessary steps in a
process as they are the root cause of waste and no value is added to the process by
them, whereas, Six Sigma states that waste actually results from variation in the
process. Both the methods being correct, are utilized by organizations as a mixed
approach of Lean Six Sigma.

Question 5: What are the gaps that can prevent optimum application of Six Sigma
methodology?

Answer:   

Insufficient data availability – It can make the process lengthy to find the root
causes that eventually delay the process.
Incorrect project selection – Many organizations select projects for Six Sigma
implementation because there are an obvious choice or other projects seem too
complicated to pick. What they don’t see is whether the projects chosen can be
implemented with Six Sigma or not

Not focusing on the voice of the customer – This leads to deviation in the goal and
ultimately hampers progress.

Hopping to implementation – Teams working on Six Sigma implementation ususally

jump straight to implementation without proper brainstorming and clear goals. This
leads to huge time waste and inappropriate implementation.

Neglecting the manpower for change – A Six Sigma implementation plan might look
brilliant on paper, but could fail in reality if changes and feedbacks from the
manpower is not considered.

Question 6:  Cite some example of Six Sigma organizations?

Answer:

 Motorola
 Mumbai’s Dabbawalas
 Amazon.com
 Boeing
 Dell
 Ford Motor Company
 United States Army and United States Marine Corps
 Wipro