Why Should I Use Six Sigma in My Projects?

Six Sigma is a structured problem-solving methodology using the DMAIC framework; one of the best ways to systematically improve your business processes is to use the DMAIC (Deh-May-Ick) framework. DMAIC is a highly effective, data-driven, five-step approach to business that is one of the many useful components of the Six Sigma toolkit. The main goal of DMAIC is to eliminate expensive variations from business and manufacturing processes.

When used together in a full Six Sigma implementation, the steps involved in DMAIC can literally turn your business around. To discover more about how you can implement this highly effective business tool in your business, take a look at this article about Six Sigma methodology.

General Motors certify me as a Black Belt in Design For Six Sigma (DFSS), and I have been applying Sig Sigma in my projects for more than seven years. This "DFSS Black Belt" certification is considered the most highly trained experts in Six Sigma, which can lead, mentor, and coach Six Sigma teams. I have extensive experience applying Six Sigma and strongly recommend it to anyone. 

What is Six Sigma?

Six Sigma (6σ) is a set of techniques & tools for process/product improvement based on "data-driven problem-solving methodology." It was introduced by American engineer Bill Smith while working at Motorola in 1986. "Six Sigma" was registered on June 11, 1991, as U.S. Service Mark 1,647,704. In 2005 Motorola attributed over US$17 billion in savings to Six Sigma [1]. By the late 1990s, about two-thirds of the Fortune 500 organizations had begun Six Sigma initiatives to reduce costs and improve quality [2].

PMBOK 6th edition is referring to "Six Sigma" as a business process improvement factor that leads to creating a project. An organization implements a project resulting from a Six Sigma value stream mapping exercise. This tool could be applied to develop, improve, or fix products, processes, or services. "Six Sigma" also referred to as a tool & technique for "quality improvement methods" of the Manage Quality process, which is the process of translating the quality management plan into executable quality activities that incorporate the organization's quality policies into the project. So, Six Sigma may improve the quality of project management and the quality of the end product, service, or result.

The Goal of Six Sigma

Six Sigma proposes to produce a process effective with 99.99996% defect-free. It means that 3.4 defects occurrence tax per million opportunities (or less) as a final result.

Six Sigma is a structured problem-solving methodology using the DMAIC framework. There are five stages in this framework. They are: 

• Define;
• Measure; 
• Analyze; 
• Improve; 
• Control.

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DMAIC Framework

Based on information from Grey Campus [3], Six Sigma Study Guide [4], and ASQ [5], the DMAIC framework would have the following steps:

Define Phase

In the Define phase, you collate a lot of information that you already have available. You will:

• Understand the project, including its purpose and scope;
• Map the current process;
• Determine whether the process is the right candidate for DMAIC;
• Detail customer expectations;
• Estimate timelines and costs;
• Create a charter containing the information above.

Measure Phase

You have mapped the existing process, you understand the project, and you have decided that this is a right DMAIC candidate. You have listed customer expectations and estimated the times and costs involved.

Your next phase involves a lot of measurements. It would be best if you had baseline figures so that you can accurately assess progress in later phases.

During this phase, you will:

• Identify the data that you need to collect;
• Decide what measurements to use;
• Figure out what methods to use to collect your measurements;
• Determine the level of variation that you will be dealing with;
• Collect the data as per previous points.

Analyze Phase

In the Analyze phase, you work with the data that you collected in the Measure phase. You will:

• Identify defect causes;
• Failure mode and effects analysis (FMEA) identifies a possible product, service, and process failures;
• Analyze these to pinpoint the root cause;
• Complex analysis tools identify the root causes of a defect. Tools like histograms, Pareto charts, fishbone diagrams are used;
• Hypotheses tests are conducted to verify and validate root causes, Viz Regression test, ANOVA test, Chi-square, etc.

Improve Phase

You have identified the root cause of your issue in the Analyze phase. Now you need to come up with a solution. You will:

• Pull in people who perform or oversee the process;
• Brainstorm potential solutions;
• Design of experiments (DOE) to solve problems from complex processes or systems where many factors influence the outcome and where it is impossible to isolate one factor or variable from the others;
• Determine the criteria for selecting a solution;
• Weigh possible solutions against the requirements;
• Pick a solution;
• Test the chosen solution;
• Measure the results and compare them to the Measure phase data.

Control Phase

Once you are happy that the chosen solution will improve the process, it is time to implement the Control phase. This is where you implement said solution, but there are some other tasks too:

• Document the solution;
• Collect data about how the solution is working in production. Statistical process control (SPC) for monitoring process behavior;
• Put supports in place to ensure that the solution is permanent, not temporary;
• 5S to create a workplace suited for visual control;
• Set up a plan to deal with any issues that might arise;
• Mistake proofing (poka-yoke) to make errors impossible or immediately detectable.

Should you use DMAIC?

Some projects are not fit for this method. For example:

• It is already obvious what the problem is and how to solve it;
• There is no or little available data on the process to be improved;
• Managers and leaders do not support improvements to this process;
• The process does not directly impact key performance indicators;
• Measuring process improvements would be difficult or impossible.

Conclusion

We should use the Six Sigma methodology in our projects because it is a worldwide famous tool for process/product improvement based on "data-driven problem-solving methodology." It is an outstanding way to make decisions based on data, not only on expectations. So, as output, your solution is more likely to create a process/product effective with 99.99996% defect-free.

Bibliography

1.  "Six Sigma: Where is it now?". Retrieved 2008-05-22.

2. De Feo, Joseph A.; Barnard, William (2005). JURAN Institute's Six Sigma Breakthrough and Beyond – Quality Performance Breakthrough Methods. Tata McGraw-Hill Publishing Company Limited. ISBN 0-07-059881-9.

3. Grey Campus. https://www.greycampus.com/blog/quality-management/a-brief-introduction-to-lean-and-six-sigma-and-lean-six-sigma

4. Six Sigma Study Guide. https://sixsigmastudyguide.com/dmaic/

5. ASQ. https://asq.org/quality-resources/dmaic