What is Six Sigma?
Six Sigma is a revolutionary set of techniques and tools designed to optimize business processes. Initially introduced by engineer Bill Smith at Motorola in 1986, Six Sigma helps practitioners identify and minimize defects and errors, reduce process variation, and significantly boost quality and efficiency using statistical analysis and project management strategies.
Six Sigma is built on five core phases known as DMAIC – Define, Measure, Analyze, Improve, and Control.
Key Takeaways
- Empower Quality Control: Businesses leverage Six Sigma to dramatically cut defects and enhance processes.
- Foundation: Developed in the 1980s by Bill Smith at Motorola.
- Profit-Boosting: Companies apply Six Sigma to streamline operations and increase profits.
- Certifications: Various certification levels modeled after martial arts belts validate Six Sigma expertise.
Understanding Six Sigma
Rooted in the belief that all business processes can be thoroughly measured and continuously improved, Six Sigma traces its origins to manufacturing as a quality control mechanism. Achieving Six Sigma quality implies a long-term defect rate lower than 3.4 defects per million opportunities (DPMO).
Over time, Six Sigma has evolved beyond manufacturing to encompass customer satisfaction, retention, and sustained improvement across diverse business products and services. One of its most renowned advocates was Jack Welch, the erstwhile CEO of General Electric.
Professionals pursuing Six Sigma certification can earn recognitions akin to martial arts ‘belts’ ranging from white to black.
The Five Steps of Six Sigma
Define
A Six Sigma expert-led team selects a process and clearly defines the issue they aim to resolve.
Measure
The team assesses the process’s current performance to establish a baseline and identifies input factors possibly affecting performance.
Analyze
The team analyzes potential root causes of process failures, systematically isolating and testing each input.
Improve
Actions are taken to implement improvements that enhance system performance.
Control
Controls are applied to ensure consistency and prevent regressions in the process.
What is Lean Six Sigma?
Lean Six Sigma merges Six Sigma methodologies with Lean Manufacturing principles to bolster performance by eliminating waste and defects while elevating work standardization. This approach focuses on significantly reducing resource waste (time, effort, talent, materials) and ensuring high-quality production and organizational processes.
Six Sigma Certification and Belt Rankings
Individuals can attest to their Six Sigma expertise through a belt-ranking certification system. The belt levels encompass:
- White belt: Basic introductory knowledge suitable for team collaboration.
- Yellow belt: Acquired through multiple training sessions, hosting project support capabilities.
- Green belt: Attained through extensive training, enabling individuals to lead project teams.
- Black belt: Advanced experts ready for leading extensive and sophisticated projects.
Black belts can advance to higher ranks such as Master Black Belt or Champion, signaling profound expertise and exceptional leadership in Six Sigma methodologies.
Real-World Examples of Six Sigma Success
Microsoft
Microsoft deployed Six Sigma to mitigate defects within its systems and data centers, harnessing standards and root-cause analysis to improve server availability and customer satisfaction.
Ventura County, CA, Government
Lean Six Sigma initiatives enabled Ventura County to save approximately $33 million by adopting efficient new systems and minimizing redundant processes. For example, improvements in vehicle maintenance scheduling saved $51,000, while a new employee leave-tracking system saved nearly $400,000 annually.
Achieving Six Sigma Certification
Six Sigma certification is available through numerous private corporations, professional associations, and some academic institutions, either via in-person or online formats. However, certification curriculums are not standardized, thus can vary.
Difference Between Six Sigma and Lean Six Sigma
Lean Six Sigma integrates Six Sigma’s structured methodology with Lean principles to minimize waste, enhancing overall operational efficiency.
The Bottom Line
Six Sigma has emerged as a transformative quality-improvement strategy across various sectors. It offers multiple certification levels for those committed to mastering its techniques, fostering robust business process enhancements and operational excellence.
Related Terms: Lean Manufacturing, Process Optimization, Quality Assurance.
References
- ASQ. “What Is Six Sigma?”
- Purdue University. ‘“Six Sigma Belt Level Rankings”.
- Microsoft. “Microsoft Announces Accelerator for Six Sigma”.
- VC Star . “Efficiency Program Rooted in Car Business Drives $33 Million in Government Savings”.
