Aakanksha Dixit 
Introduction
Organizations equipped with vast amounts of services and products may sometimes find defects or problems in their products or services. In order to overcome these flaws before providing a service to other agencies, there are some platforms like six sigma, which help to minimize the defects to a great extent. In this blog post, we will discuss the six sigma, why six sigma, history, six sigma methods and the tools used by six sigma users. This six sigma for beginners mainly benefits the individual and professionals for the acquisition of knowledge about six sigma functions. Become successful in Six Sigma with our professional Six Sigma Certification Course and get certified.
What is Six Sigma?
Six Sigma is a popular discipline or process where you can focus on developing highly accurate or near-to-perfect products and services consistently. The aim of this process is to eliminate waste and deliver the best defects-free product as needed by customers. Based on the structured methodology followed by the process, will define the role of participants. Build job-ready skills for an in-demand career as a Business Analyst with globally recognized Business Analyst Courses.
This is data-driven, where we need more accurate data or information to initialize the processes. This is all about putting results on Financial Statements. The sigma is a statistical work that will define how a given process deviates by achieving perfection. The concept was discovered by Motorola in the 1980s due to an increase in product failures and defects. The thoughts of Bill Smith did magic but he soon died of a heart attack in Motorola Cafeteria in 1993. It is based on many quality management theories for the delivery of an error-free product at the client end.
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What are the Features of Six Sigma?
Six Sigma is a method of continuous improvement in customer satisfaction and profitability. Six Sigma's concept has a simple objective: to provide nearly perfect goods and services for business transformation in order to optimize customer satisfaction. See the infographic below to understand better-
Here are some of its features-
- Six Sigma's goal is to eliminate waste and inefficiencies, increasing customer satisfaction by delivering what they expect.
- Six Sigmas follow a structured methodology, with defined roles for participants.
- Six Sigma is a data-driven methodology that requires accurate data to be collected for the processes analyzed.
- Six Sigma is a multi-dimensional structured approach for process enhancement, defect reduction, lowering costs, increasing profits and customer satisfaction.
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What are the Key Elements of Six Sigma?
Six Sigma is dissected into three core elements. They are- The Customers, The Processes and The Employees.
- Customers will define the quality in terms of reliability, performance, costs, deliveries, time frame, services and more.
- A Process is defined as the series of steps that are undertaken to design a product or service as per customer needs and expectations. The four pillars of the process include – input, steps, output, and feedback. The process followed by Six Sigma is DMAIC whose meaning is Define, Measure, Analyze, Improve, and Control.
- Employees are involved in the Six Sigma program and focus on their capabilities to satisfy customers to a larger extent.
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Why Use Six Sigma?
The ultimate goal of any project or organization is to obtain the highest level of client satisfaction. Let's try to understand the various benefits or merits of Six sigma and why the company prefers a Six Sigma certified professional:
- Customer Satisfaction- Six Sigma tends to increase client satisfaction by reducing potential problems and eliminating undesirable specifications from the process. Six sigma helps drive customer loyalty and loyalty.
- Eradication of Waste- Six Sigma is a data-driven approach to reducing unwanted players in the process that eradicates variation. Six Sigma helps identify areas of improvement in the process.
- Time Management- Six Sigma focuses on business efficiency and productivity enhancement by helping employees manage their time efficiently.
- Career Advancement- Having Six Sigma certification helps you stay out of the crowd and provides you with additional advanced skills that are highly required by the company. In this way, the Six Sigma certification helps you improve your career and guides you forward one step ahead of the competition.
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The Six Sigma Methodology
Before we discuss the process approach followed by Six Sigma, let us have a quick look at how it works actually. Six Sigma is a quality management strategy where an environment is provided by management to support the Six Sigma program not as a standalone approach to satisfy someone's needs. This will emphasize DMAIC process methodology largely to solve any problem.
Further, the Employees or Six Sigma team are assigned projects that will directly impact the bottom line of an organization and maintain quality as per customers’ expectations. The Six Sigma concept is highly based on statistical techniques and also needs a little knowledge of statistical concepts for the best implementation of the program. Now, let us discuss in detail what is DMAIC and the list of DMAIC tools one by one.
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What is DMAIC?
The process followed by Six Sigma is DMAIC whose meaning is Define, Measure, Analyze, Improve, and Control.
- During the Define Phase, we have to define the problem statement and the relevant plan for improvements too.
- In the Measure phase, we have to collect the data and find out the current quality trends and performance levels.
- In the Analysis Phase, we need to define the measurement criteria for how to check the quality embedded within a product and the possible number of associated defects.
- In the Improvement Phase, we will define the significant area of improvement based on each error type.
- In the end, the Control phase, the Six Sigma team will undergo the full-scale implementation and control or monitor the system consistently to sustain the gains.
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A List of DMAIC Tools
There is a particular set of tools for each phase of the Define, Measure, Analyze, Improve, and Control process.
- Tools for Define Phase: Supply, Input, Process, Output, Customer or SIPOC Diagram, Voice of Customer or VOC (Pronounce as: V-O-c), Critical to Quality or CTQ Trees, Quality Function Deployment or QFD, Failure Mode and Effects Analysis or FMEA, Cause and Effect or CE Matrix, and Project Charter.
- Tools for Measure Phase: GAGE R and R Variables, Run Charts or Control Charts, Cp, Cok, Sigma level (Z Level) and Defects per Million Opportunity or DPMO, and Anderson Darling Test
- Tools for Analysis Phase: Simple Linear Regression, Fishbone Diagram, Pareto Charts, FMEA, and Multi-Vari Charts or Hypothesis Tests
- Tools for Improvement Phase: Brainstorming, Design of Experiments or DOE and Piloting and FMEA
- Tools for Control Phase: Measurement System Analysis or MSA Re-analysis, Control Charts, and Control Plan
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DFSS is a business process methodology that makes sure that every new product is designed as per customer needs and expectations and that products are already at six sigma levels or not. For this purpose, the organizations will be using a variety of tools like QFD or FMEA that would help in measuring the quality standards as defined by the customers. These tools can also be used to give an entirely new category of products to customers.
With the help of DFSS, you can always improve the current service lines or product standards. If you wanted to implement the DFSS then the business system should be sure of customer requirements at the first level. So, we can say that DFSS is simply used to design a new product or service as per customer expectations. Let us now see DFSS tools and how they are helpful for some organizations.
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QFD – Quality Function Management
QFD is a predefined standard for identifying or implementing customer requirements. This is a systematic approach to understanding customer needs and converting them into a set of designs. Also, the tool will make sure that customer needs and expectations can be met in less time and at manageable costs. The tool makes us realize how much the customer needs are important to us and what are the strengths and weaknesses of an organization.
As per QFD guidelines, you should design a set of questions to ask the customers and check what would happen if any product or service used by the customer fails. So, you have to understand the effect of failure and take the necessary steps to prevent damage during the event of failure. Now, let us move to our next tool i.e. FMEA.
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FMEA – Failure Modes and effect analysis
FMEA means Failure modes and effects analysis, this is a pre-emptive tool helping a system in the identification of the potential pitfalls at different levels of a business system. Also, it helps organizations in identifying and prioritizing the things during the event of failure and determining the effect of failure on customers as well. So, you will get a list of critical areas that are necessary to focus on to avoid failures. Keep in mind that FEMA could identify the critical areas but it cannot offer solutions to the identified problems. Let us further look at the categories of FEMA – these are DFMEA and PFMEA.
PFMEA means Process Failure modes and effects analysis and DFMEA means Design Failure modes and effects analysis. PFMEA is used when a new process is introduced to the system to uncover the hidden issues and how it can affect the system. At the same time, FMEA is used in the design phase to find out the failure modes and their effect on the system. It is generally performed before the product is sent to manufacturing and all design deficiency should be sorted out by the end of this process. Now let us see what FMEA Risk Priority Number RPN is.
With the FMEA RPN, you could quantify or assess the risks associated with the process or design of a system. The higher the RPN, the higher the priority received by the product or process. RPN is generally defined as the product of the severity of failures, the occurrence of failures, and the detectability of failure. With the help of these three values, it is always easy to manage a product and ensure the safety of most critical operations. The next important term is the FMEA table. With the help of FMEA, you can define the checklist of why defects occurred and how you can cure them. This table can be used for future references later.
After this section, we come to the end of our blog Six Sigma Tutorial Guide and cover all important topics that are necessary to learn for beginners. So, now you would be able to define what is Six Sigma, its benefits, key concepts, DMAIC methodology followed by the Six Sigma, DMAIC tools, and DFSS (Design for Six Sigma) etc. One more important term is Lean Six Sigma which would be covered in one of the other blogs in detail.
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Career Opportunities in Six Sigma
There are several career options for Six Sigma professionals as manufacturing engineers, compliance engineers and operational systems specialists. An aspirant can look into any of the job roles like Six Sigma Analyst, Six Sigma Black Belt, Senior Project Manager, Six Sigma Consultant and many more. In India, a Six Sigma Black Belt salary ranges from 7.2 lacs- 28 lacs with an average annual salary of 17.6 lacs p.a according to AmbitionBox. There are about 10k + job vacancies in Six Sigma on LinkedIn. See the graph to understand certified vs non-certified Six Sigma professionals.
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Conclusion
In short, the adoption of six sigma not only stimulates the growth of the organization but also advances a person's career. Today's organizations are looking for six sigma certified professionals to enhance their quality of service. Professionals trained in the Six Sigma guidelines gain some skills and knowledge of useful tools for identifying areas for improvement. Earn a Six Sigma Certification Course to explore your potential growth in the relevant field.
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