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Process perfection would be the right introduction to Six Sigma. It is statistic-based process melioration methodology used in business firms. It aims at making the process more effective and reliable by limiting the possibility of number of defects to less than 3.4 defects per million opportunities by banking heavily on statistical techniques. Six Sigma is a quality control mechanism, based totally on data and facts rather than relying on assumptions.
“Sigma” means the standard deviations in mean. Sigma is the 18th letter in the Greek alphabet, represented by the symbol "σ" and it exemplifies the standard deviations in statistics. Bill Smith at Motorola originally articulated Six Sigma in 1986. [Source: Motorola website] Six Sigma is the registered trademark of Motorola Inc. The following table exemplifies well the degree of Sigma level along with its DFMO:
Sigma Level Defects-Per-Million-Opportunities
1 σ 690,000
2 σ 380,000
3 σ 66,800
4 σ 6210
5 σ 230
6 σ 3.4
Essentials of Six Sigma: - Owing to the fact that satisfying the customers is of utmost importance for leading any process to the pinnacles of success, the needs and the demands of customers are kept in mind.
- The deviations shown by the processes are calculated by relying on facts and data rather than assumptions. The variations, which may create problem for any process and may hinder its progress, are identified and necessary steps are taken to eliminate the cause of the same.
- More vehemence on the amelioration of the process is given to step-up the quality of the product and thereby achieving the customer satisfaction. Moreover, efficacious measures are followed to reduce the number of possible defects.
- Organizational communication is improved because of which the new problem solving methods and techniques are conveyed and shared with the other members of the organization.
- The short-term and long-term goals of the process are defined, keeping in mind the customer satisfaction, the quality level of the product and the on-time delivery of the product.
Working of Six Sigma:
DMAIC (Define-Measure-Analyze-Improve-Control) and DMADV (Define-Measure-Analyze-Design-Verify) are the two methodologies Six Sigma uses to execute any process. The former is meant for process improvement while latter, also known as DFSS (Design-For-Six-Sigma), is meant for new products and its designs. DMAIC states the following points: - Define: This stage deals with identifying the needs and the requirements of the customers. The desired objectives and goals of the process are determined and thereby defined, based on the requirements of the customers.
- Measure: The capability of the process, in terms of the defined objectives and goals, is determined by measuring its performance.
- Analyze: The variations between the current performance and the desired output are analyzed. The factors responsible for these variations are identified and possible measures are taken to eradicate the root causes of such variations.
- Improve: Six Sigma aims at continuously improving the process by implementing necessary, utile changes into it, to wipe out the occurred problems.
- Control: The performance of the process is controlled by implementing the new changes made to the process under a controlled plan.
DMADV, also known as DFSS i.e. Design for Six Sigma, states the following points: - Define: This stage deals with the designing of the process its desired objectives.
- Measure: The various components associated with the designing of the process, such as consumer satisfaction, corporate waste, risks etc. are determined.
- Analyze: The capability and the performance of the design is analyzed.
- Design: The changes, which are to be implemented into any design or the details of any new design are analyzed and informed to the management department for its confirmation.
- Verify: The design is analyzed and verified. It is then sent to the process owner for its confirmation.
Why is Six Sigma Used? - The quality of the product and the productivity of the company improve immensely.
- The number of possible defects per million opportunities reduces immensely. Thus, the quality of the product improves further.
- The result of any process is defined, based on collective data and facts rather than assumptions.
- The profit-level of the company increases immensely and thereby provides a growth in the corporate sector.
- It calls for a more integrated and correlated approach to solve the existing problem.
- Rather than adopting the conventional cost cutting method, it prefers removing costs that give no value to the customers.
- The net production cost incurred while manufacturing a product reduces.
- By reducing the number of defect, it provides the company a ray of hope for higher expectations.
- The need and expectations of the customers are met by providing them the same product with a better quality.
- The internal understanding between the departments increase, thereby the employees tend to be more aware of the techniques and strategies used for solving a particular problem.
- There is a better prospect of job satisfaction for employees, because of which, the internal communication within the organization increases.
- The production time spent while manufacturing a product decreases; thereby the delivery of the service is fast.
- The market value of the company improves.
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