Introduction to Six Sigma Quality
Six Sigma is a popular technical tool used for the improvement of the quality of products and services within the organization. Six Sigma is a management design that emphasizes the focus on managing a business while improving a process using statistical tools. Six Sigma evolution was done from management science; it is a data-driven approach to obtain high performance; this approach analyses the root cause of the failure in the business and provides suitable solutions. It forms a bridge between financial results, improvement in process, and customers.
Six Sigma was introduced for Motorola in the 1980s by Bill Smith. He used the six sigma methodology to measure the quality of products and services in the company. Management philosophers say that the business is reorganized by adopting better and improved versions and assuring changes in the results. The strategy is made for improvement if defects are found; the aim is to provide excellent (efficient) products and services. Six Sigma tools are the best way to understand the needs of the customer; every detail is taken on the serious node.
Qualities of Six Sigma
Given below is the list of some essential qualities of Six Sigma:
1. Six Sigma Power
Six sigma themes are defect-free, approximately 99.99966%, which calculates the efficient solution to every issue in the business. The statistical unit is used to measure the efficiency of the issues, near perfection level solution. Six Sigma does implement (by statistics) by collecting data and predicting results; when satisfied, information is integrated into industrial processes. However, it reduces variation and increases the quality of the deliverables; it can not instantly improve the speed of the process, nether it can reduce invested capital. So, lean is made a combination, and lean six sigma is the new way to work on its short come. Lean six sigma maximizes the value by improving customer satisfaction, cost, quality, and the process’s speed, and invested capital is also lowered.
2. Six Sigma Methodology
Six Sigma methodology’s last aim is to create output that is exactly the same as demanded by the consumer; it can be done by cutting all sources which can produce defects and reducing unwanted activities from the pipeline. While using the six sigma technique, it is meant that the product and services produced will be defect-free (almost), its methodology put more focus on the customer, create a draft clearly for customers demand, then uses facts and data to bring out a better product. To create a new product, all internal and external resources are used; evaluated data, statistical methodology, and other relevant metrics are key to getting a better result. Six Sigma implementation needs good communication among the teams because, during the planning phase, it leaves a big room for interpreting new add on for adaptability, the clear draft is presented, which larger parts can be used and what parts can be decomposed for different solutions.
In every process, it works in a way that it can be evaluated and improved at every stage in terms of:
- Response in no time.
- Used quantities in product development.
- Performance quality.
- Quality of design.
- Confirmation of quality (that’s the priority).
- And all processes included for deliverables.
This keeps open room for quality improvement by using problem-solving tools and methods before actually delivering the product. Six Sigma uses 2 different methods for problem-solving: DMAIC and DFSS. DMAIC method is used for running processes, while DFSS is used in optimizing a design process.
3. DMAIC of Six Sigma
- Define: It is the starting stage where the team identifies the poor function areas of the organization identify and define. Feasible and cost analysis is done for detecting the cost implications and the financial benefit impacts. The identified attributes of the products are considered profitable by the customer during the evaluation of the product quality.
- Measure: The data is collected to identify the issues and the root cause of the issue within the process. The statistical method is used to determine the accuracy within the process to know the exact error rate. Flow charts, FMEA (failure mode effects analysis), effect diagrams and all are used to measure the defects. This stage keeps a record of original data because this data is used throughout the process to keep records and improvement throughout the process.
- Analyze: The data (and the team) is critically interrogated that can define the process and its issues. These questions are about what and what percent, and where and how and what is the percentage of the defect. All the defects whether its human defect or machinery defects all are identified and resolved accordingly.
- Innovate: During this phase, several solutions are tried to eliminate the error, scientific principal, managerial approaches, and technical concepts are used; brainstorming is the important part here, which helps in bringing out innovative ideas to choose among ideas for the proper solution.
- Improve: The focus is put on the design, which can be modified and adjusted to get the improved level. Various simulations and optimizing techniques can be used. The key variables are fixed and kept under the validation limit; the improvement process is carried out within the variables in limits.
- Control: Once the DMAIC is started, starting 3 steps characterize the process, and the last 3 steps optimize the process; after starting the process, this must be managed regularly to attain the benefits and sustain benefits. The process is monitored at regular intervals to assure that the key variables are safe.
In the above 6 steps, Six Sigma leaders define the motive of the project and gather the tools necessary for action to resolve the problems. Then the team analyze the voice of the customer and identify CTC. To follow the Six Sigma draft, the team must calculate CTQs (critical to quality).
4. Benefits of Using Six Sigma
It induces a change in the management style and produces a culture of error/defect-free production, cost control, and a customer satisfaction environment with employees.
- It reduces defects.
- It also reduces production costs.
- Keep control of competitive pricing.
- It is a customer-focused approach.
- Gains high productivity.
- High returns on investments are gained.
This has been a guide to Six Sigma Quality. Here we discussed the basic concept, power, methodology, DMAIC and benefits of using Six Sigma. You may also look at the following article to learn more –