Introduction to Six Sigma
History, Concepts, and Implementation
History of Six Sigma
- Six Sigma was invented by Motorola in 1987
- General Electric implemented Six Sigma in all processes
- Managers in General Electric were required to go through Six Sigma training
What is Six Sigma?
- Six Sigma aims for high-performance standards
- The goal is to achieve 3.4 defects per million opportunities
- It involves using half the tolerance to ensure quality
- Three broad approaches: statistical tool, process improvement, and philosophy
Approaches to Six Sigma
- Statistical tool approach aims for less than 3.4 defects per million opportunities
- Process improvement approach using DMAIC (Define, Measure, Analyze, Improve, Control)
- Philosophical approach seeks continuous improvement
- Most organizations implement Six Sigma as statistical tool or process improvement
Defect Levels and Sigma Numbers
- Defect levels measured in defects per million opportunities
- Higher defect levels correspond to lower sigma numbers
- 3.4 defects per million opportunities represents Six Sigma performance
- As defect levels increase, sigma levels decrease
DMAIC Approach for Process Improvement
- DMAIC stands for Define, Measure, Analyze, Improve, Control
- Used to improve existing processes
- Identify the problem, measure the current performance, analyze root causes, implement improvements, and establish control measures
DMADV Approach for Process Design
- DMADV stands for Define, Measure, Analyze, Design, Verify
- Used for designing new processes
- Focuses on developing new processes to meet customer requirements
Six Sigma Belts
- White belt - basic understanding of Six Sigma
- Yellow belt - participate in Six Sigma improvement teams
- Green belt - lead small projects or support Black belts
- Black belt - full-time job, lead complex improvement projects
- Master Black belt - trains and mentors other belts