Manufacturing Technology

Six Sigma
John Dabin
Ruslan Dautov
Younes El Bouchttaoui

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Introduction
Aim: Quality and Process
improvement
Invented in 1986 by Motorola
Applied first to industrial processes.
Applied now also to any process where
the outcome is measurable

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Meaning and Math

Sigma stands for the Standard Deviation
(SD): measure of the amount of
dispersion from the average

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Meaning and Math (2)

Six Sigma: Aim is that the components
are maximum 3sigma far from the
average. (Low and high specification)
3.4 defective parts/million

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Meaning and Math (3)

Six sigma and corresponds actually to a
sigma value of 4.5

Long-Term Dynamic Mean Variation:

processes vary and drift over time
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Philosophy
Statistical measures are taken on the
components.
A Sigma level is computed
Processes are improved in order to reach
the desired sigma level.
Each project fixes its desired sigma level
Global mindset: Produce right, delete the
causes of variation

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Efficiency & Examples

4.6 = 99.9%
4000 wrong medical prescription/year
400 letters lost/day

6 = 99,9997%
13 wrong medical prescription/year
1 letter lost/day

Not every process need 6

IRS phones in tax advice: 2,2

Airline baggage handling: 3,2
Quality products & services: 5,7
Digital watch: 6
Airline industry fatality rate: 6,2
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Methodology: DMAIC
Six Sigma Improvement Methodology
1.
1.
2.
3.
4.

Define: Goals of improved activity. What?

Measure: existing system and defects.
Analyze: eliminate gap
Improve:
Control: future of process deviation from target

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Methodology: DMADV
New process along with six sigma
1.
2.
3.
4.
5.

Define: design goals - customer

Measure and Identify: CTQs, capabilities
Analyze: to develop - design
Design: improved alternatives
Verify:design, implement process

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Tool: 5 Whys
5?
Question asking tool cause and effect
Example: coolant leaking from machine
1.
2.
3.
4.
5.

Coolant is leaking. WHY?

Seat on coolant wall is damaged. WHY?
Metal shaving got into coolant. WHY?
Screen on coolent regulating Pump is broken. WHY?
Screen is located at a place where it was likely to be
damaged by dropped parts. Root cause.

.Solution:
Redesign machine
Add guard to the screen
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Tool: 5 Whys (2)

Questioning: > iterations
Advantages
Simple technique: root cause

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Key Roles
Organizational level:

Executive leadership
Champions

Project level:

Master Black Belts

Black Belts
Green Belts
Yellow Belts

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Recognition and Accreditation

Certification
to display proficiency in the subject matter
to increase desirability by employers
to potentially increase your salary

Accreditation
Let market know youre reliable
Complying with best practices
Distinguish yourself for the consumer and gain important
visibility in the market

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Lean Six Sigma

Six Sigma focuses on Quality
Methodology
Defect reduction

Lean focuses on Speed

Process Analysis
Shorter, less complex problems
Cycle time reduction
Elimination of waste

Improving and streamlining the the process

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Companies that use Six Sigma

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It takes money to make money

Revenue
($B)

Savings
($B)

% Revenue
Savings

Motorola
(1986-2001)

356.9

16

4.5

GE
(1996-1999)

382.1

4.4

1.2

Honeywell
(1998-2000)

72.3

1.8

2.4

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Conclusion
Six Sigma is not:

A standard
A certification
Another metric like
percentage

Rather!
Way of improving
performance by knowing
where you are and where
you could be.
Methodology to measure
and improve companys
performance, practices and
systems

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