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An Inside Look at
Six Sigma at GE
THE STORY OF THE
COMPANYS SIX SIGMA
NOTE: This article is excerpted from Leading Six Sigma: How To Break Through the
Six Sigma Hype and Radically Improve Your Business by Ronald Snee and Roger
Hoerl. The book will be published by Financial Times Prentice Hall in Fall 2002.
EXPERIENCES, FROM
THE BEGINNING.
By Roger
Hoerl, General
Electric Co.
great deal has been written about General Electrics (GE) Six Sigma
initiative; in fact, it has pretty much been beaten to death in the
media. However, while some of the published material on GEs Six
Sigma experiences has been accurate, much has been written from questionable second- or thirdhand sources and reads to those inside GE much like a
Tom Clancy novel: captivating, but pure fiction.
It seems everyone is an expert on what happened at GE, and it is becoming
difficult to separate fact from the myths that have sprung up. For example,
readers of popular management books and articles on Six Sigma might come
to one or more of the following erroneous conclusions:
GEs Six Sigma deployment was easy (it wasnt).
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GEs research center MVP (most valuable player) Award winners and
their managers. The award winners are holding their products developed
through Design for Six Sigma.
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Science Day at the research center. Employees share aspects of applied science
with area schoolchildren.
A Refocus on Customers
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1. Reduce average and variation in days outstanding of accounts receivable. Collect money faster.
2. Optimize timing of invoice payment in accounts payable. Pay in time to collect discounts, but otherwise hold on to the
money as long as the terms allow.
3. Manage costs of public accounting firms. Investigate why you sometimes pay more per hour than other times and why
you sometimes have highly paid accounting people doing lower level work.
4. Skip tracing in collections. Determine financially optimal strategies for finding consumers who have skipped on
accounts.
5. Determine the best way to factor inventory. Pay a third party to hold it on their books. Take into account several criteria, including net income and cash flow.
6. Determine the best way to factor accounts receivable. Sell your accounts receivable to a third party to enhance cash
flow, while maintaining profitability.
12. Hedge foreign currencies. Improve how you convert foreign currency to U.S. dollars. Because all financial measures are
generally reported in dollars, this can have a huge impact on the bottom line for international companies.
13. Reduce variation in cash flow. Sometimes cash flow follows profitability, sometimes it doesnt. Why? Because theres
so much creative accounting today analysts often want an explanation if cash flow isnt increasing at the same rate as
earnings.
14. Credit score to improve your ability to predict which individuals or businesses are good credit risks and which arent.
15. Make accurate journal entries. A common rule of thumb says most businesses have a 3 to 4% error rate in journal
entries, which results in a lot of rework.
18. File federal, state and local taxes to reduce cycle time and make sure you are not overpaying.
19. Better manage the pension fund by obtaining higher rates of return. The federal government requires certain reserves,
but if you manage the pension fund well, you can take the overfunded amount to the bottom line.
20. Ensure payroll accuracy, including deductions for taxes and benefits.
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Some of the
A Reinvigoration in 2001
In 2001, Jeff Immelt announced a reinvigoration of
Six Sigma. This was an important step symbolically
because there was some concern the emphasis on Six
Sigma might decline once Jack Welch retired.
The reinvigoration included a push to further
increase the percentage of senior executives with dedicated Six Sigma experience, acceleration of ACFC
projects (of which there are more than 10,000
planned for 2002) and standardization of BB course
material and certification criteria across the company.
Looking into the near future, one could anticipate
further integration of Six Sigma into the supply chain,
working with both customers and suppliers on joint
training and applications.
It also looks as though Six Sigma will remain a cornerstone of GEs executive development system.
Speculation has been swirling for some time that the
company will get into the Six Sigma consulting business, but there is no indication to date of this actually
happening.
Going forward, the greatest challenge will be ensuring the focus remains on tangible results and does not
regress into the bureaucratic ticket-punching exercise
many companies have experienced with various
improvement initiatives.
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REFERENCES
1. GEs 2000 Annual Report, www.ge.com/annual00/index.html.
2. S.M. Paton, First Word, Quality Digest, August 2001.
3. Anonymous, Last Word, Quality Digest, August 2001.
4. Gerald J. Hahn, Necip Doganaksoy and Roger W. Hoerl, The Evolution
of Six Sigma, Quality Engineering, Vol. 12, No. 3.
5. GEs 1998 Annual Report, www.ge.com/annual98/index.htm.
6. Ibid.
7. Rekha Agrawal and Roger W. Hoerl, Commercial Quality: The Next
Wave in Statistical Thinking, Proceedings of the Section on Physical and
Engineering Sciences (Alexandria, VA: American Statistical Association, 1999).
8. R.W. Hoerl, Six Sigma Black Belts, What Do They Need to Know?
Journal of Quality Technology, Vol. 33, No. 4.
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9. Bob Violino, E-business Leaders Light the Way, InternetWeek, June 12,
2002, special edition.
10. GEs 2000 Annual Report, www.ge.com/annual00/index.html.
11. GEs Web site, www.ge.com.