What is a Six Sigma quality program?

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Six Sigma is a business management strategy which aims at improving the quality of processes by minimizing and eventually removing the errors and variations.

The concept of Six Sigma was introduced by Motorola in 1986, but was popularized by Jack Welch who incorporated the strategy in his business processes at General Electric.

The concept of Six Sigma came into existence when one of Motorola’s senior executives complained of Motorola’s bad quality. Bill Smith eventually formulated the methodology in 1986.

Quality plays an important role in the success and failure of an organization. Neglecting an important aspect like quality, will not let you survive in the long run. Six Sigma ensures superior quality of products by removing the defects in the processes and systems.

Six sigma is a process which helps in improving the overall processes and systems by identifying and eventually removing the hurdles which might stop the organization to reach the levels of perfection.

According to sigma, any sort of challenge which comes across in an organization’s processes is considered to be a defect and needs to be eliminated.

Organizations practicing Six Sigma create special levels for employees within the organization. Such levels are called as: “Green belts”, “Black belts” and so on. Individuals certified with any of these belts are often experts in six sigma process.

According to Six Sigma any process which does not lead to customer satisfaction is referred to as a defect and has to be eliminated from the system to ensure superior quality of products and services. Every organization strives hard to maintain excellent quality of its brand and the process of six sigma ensures the same by removing various defects and errors which come in the way of customer satisfaction.

The process of Six Sigma originated in manufacturing processes but now it finds its use in other businesses as well. Proper budgets and resources need to be allocated for the implementation of Six Sigma in organizations.

Following are the two Six Sigma methods:

DMAIC focuses on improving existing business practices. DMADV, on the other hand focuses on creating new strategies and policies.

DMAIC has Five Phases

D - Define the Problem. In the first phase, various problems which need to be addressed to are clearly defined. Feedbacks are taken from customers as to what they feel about a particular product or service. Feedbacks are carefully monitored to understand problem areas and their root causes.

M - Measure and find out the key points of the current process. Once the problem is identified, employees collect relevant data which would give an insight into current processes.

A - Analyze the data. The information collected in the second stage is thoroughly verified. The root cause of the defects are carefully studied and investigated as to find out how they are affecting the entire process.

I - Improve the current processes based on the research and analysis done in the previous stage. Efforts are made to create new projects which would ensure superior quality.

C - Control the processes so that they do not lead to defects.

DMADV Method

D - Design strategies and processes which ensure hundred percent customer satisfaction.

M - Measure and identify parameters that are important for quality.

A - Analyze and develop high level alternatives to ensure superior quality.

D - Design details and processes.

V - Verify various processes and finally implement the same.

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Six Sigma is a process that makes use of statistics and data analysis to analyze and reduce errors or defects. In this process, the purpose is to improve cycle times while reducing manufacturing defects to no more than 3.4 defects per million units or events.

Six Sigma is a method that offers organizations tools to improve their capabilities in managing their businesses. This increase in performance and decreasing process variation, it is possible to reduce defect rates, improve employee morale, and improve the quality of products or services, which all contribute to a higher level of profitability.

Six Sigma is a set of management tools and techniques designed to improve the capability of the business process by reducing the likelihood of error. Six sigma is a data-driven approach that uses a statistical methodology for eliminating defects, defect reduction and profits improvement.

Digital transformation has become the hottest buzzword of this decade. New technologies and tools are supporting the transformation journey of companies big and small as they compete to get a bigger slice of business in a fast-paced competitive environment. Yet, is it enough to smooth a company's transformative process? Can a standalone technology implementation remove a bottleneck in the production process or support troubleshooting a service design flaw? Although digital transformation fast-tracks a company's growth, it has to be equally supported by management methods of quality control and business transformation.

Keeping in tune with emerging markets and processes, the American company Motorola developed a new concept of quality management process in 1986. Over the years, it has been refined and polished into a sound theory of principles and methods, aimed at business transformation through a clearly defined process. This finished product is Six Sigma. And in this article, we will cover the following topics in detail:

What is six sigma?
The 5 key principles of six sigma
The six sigma methodology
The six sigma process of business transformation
Top six sigma techniques
Top 7 six sigma tools
Six sigma levels
Six sigma certification levels
Various career opportunities and salary aspects
Top six sigma learning resources

The etymology is based on the Greek symbol "sigma" or "σ," a statistical term for measuring process deviation from the process mean or target. "Six Sigma" comes from the bell curve used in statistics, where one Sigma symbolizes a single standard deviation from the mean. If the process has six Sigmas, three above and three below the mean, the defect rate is classified as "extremely low."

The graph of the normal distribution below underscores the statistical assumptions of the Six Sigma model. The higher the standard deviation, the higher is the spread of values encountered. So, processes, where the mean is minimum 6σ away from the closest specification limit, are aimed at Six Sigma.

Credit: Cmglee, via Wiki Creative Commons CC BY-SA 3.0

The concept of Six Sigma has a simple goal – delivering near-perfect goods and services for business transformation for optimal customer satisfaction (CX).

Goals are achieved through a two-pronged approach:

Six Sigma has its foundations in five key principles:

This is based on the popular belief that the "customer is the king." The primary goal is to bring maximum benefit to the customer. For this, a business needs to understand its customers, their needs, and what drives sales or loyalty. This requires establishing the standard of quality as defined by what the customer or market demands.
Map the steps in a given process to determine areas of waste. Gather data to discover the specific problem area that is to be addressed or transformed. Have clearly defined goals for data collection, including defining the data to be collected, the reason for the data gathering, insights expected, ensuring the accuracy of measurements, and establishing a standardized data collection system. Ascertain if the data is helping to achieve the goals, whether or not the data needs to be refined, or additional information collected. Identify the problem. Ask questions and find the root cause.
Once the problem is identified, make changes to the process to eliminate variation, thus removing defects. Remove the activities in the process that do not add to the customer value. If the value stream doesn't reveal where the problem lies, tools are used to help discover the outliers and problem areas. Streamline functions to achieve quality control and efficiency. In the end, by taking out the above-mentioned junk, bottlenecks in the process are removed.
Involve all stakeholders. Adopt a structured process where your team contributes and collaborates their varied expertise for problem-solving.
Six Sigma processes can have a great impact on an organization, so the team has to be proficient in the principles and methodologies used. Hence, specialized training and knowledge are required to reduce the risk of project or re-design failures and ensure that the process performs optimally.
The essence of Six Sigma is business transformation and change. When a faulty or inefficient process is removed, it calls for a change in the work practice and employee approach. A robust culture of flexibility and responsiveness to changes in procedures can ensure streamlined project implementation. The people and departments involved should be able to adapt to change with ease, so to facilitate this, processes should be designed for quick and seamless adoption. Ultimately, the company that has an eye fixed on the data examines the bottom line periodically and adjusts its processes where necessary, can gain a competitive edge.

The two main Six Sigma methodologies are DMAIC and DMADV. Each has its own set of recommended procedures to be implemented for business transformation.

DMAIC is a data-driven method used to improve existing products or services for better customer satisfaction. It is the acronym for the five phases: D – Define, M – Measure, A – Analyse, I – Improve, C – Control. DMAIC is applied in the manufacturing of a product or delivery of a service.

DMADV is a part of the Design for Six Sigma (DFSS) process used to design or re-design different processes of product manufacturing or service delivery. The five phases of DMADV are: D – Define, M – Measure, A – Analyse, D – Design, V – Validate. DMADV is employed when existing processes do not meet customer conditions, even after optimization, or when it is required to develop new methods. It is executed by Six Sigma Green Belts and Six Sigma Black Belts and under the supervision of Six Sigma Master Black Belts. We'll get to the belts later.

The two methodologies are used in different business settings, and professionals seeking to master these methods and application scenarios would do well to take an online certificate program taught by industry experts.

Although what is Six Sigma uses various methods to discover deviations and solve problems, the DMAIC is the standard methodology used by Six Sigma practitioners. Six Sigma uses a data-driven management process used for optimizing and improving business processes. The underlying framework is a strong customer focus and robust use of data and statistics to conclude.

The Six Sigma Process of the DMAIC method has five phases:

Each of the above phases of business transformation has several steps:

The Six Sigma process begins with a customer-centric approach.
Step 1: The business problem is defined from the customer perspective.

Step 2: Goals are set. What do you want to achieve? What are the resources you will use to achieve the goals?
Step 3: Map the process. Verify with the stakeholders that you are on the right track.
The second phase is focused on the metrics of the project and the tools used in the measurement. How can you improve? How can you quantify this?
Step 1: Measure your problem in numbers or with supporting data.

Step 2: Define performance yardstick. Fix the limits for "Y."
Step 3: Evaluate the measurement system to be used. Can it help you achieve your outcome?
The third phase analyzes the process to discover the influencing variables.
Step 1: Determine if your process is efficient and effective. Does the process help achieve what you need?

Step 2: Quantify your goals in numbers. For instance, reduce defective goods by 20%.
Step 3: Identify variations using historical data.
This process investigates how the changes in "X" impact "Y." This phase is where you identify how you can improve the process implementation.
Step 1: Identify possible reasons. Test to identify which of the "X" variables identified in Process III influence "Y."

Step 2: Discover relationships between the variables.
Step 3: Establish process tolerance, defined as the precise values that certain variables can have, and still fall within acceptable boundaries, for instance, the quality of any given product. Which boundaries need X to hold Y within specifications? What operating conditions can impact the outcome? Process tolerances can be achieved by using tools like robust optimization and validation set.
In this final phase, you determine that the performance objective identified in the previous phase is well implemented and that the designed improvements are sustainable.
Step 1: Validate the measurement system to be used.

Step 2: Establish process capability. Is the goal being met? For instance, will the goal of reducing defective goods by 20 percent be achieved?
Step 3: Once the previous step is satisfied, implement the process.

Interested in learning Lean Six Sigma and it’s importance? Check out the Green Belt Certification course preview!

The Six Sigma methodology also uses a mix of statistical and data analysis tools such as process mapping and design and proven qualitative and quantitative techniques, to achieve the desired outcome.

Fig: Key Six Sigma Techniques in use

Brainstorming

Brainstorming is the key process of any problem-solving method and is often utilized in the "improve" phase of the DMAIC methodology. It is a necessary process before anyone starts using any tools. Brainstorming involves bouncing ideas and generating creative ways to approach a problem through intensive freewheeling group discussions. A facilitator, who is typically the lead Black Belt or Green Belt, moderates the open session among a group of participants.

Root Cause Analysis/The 5 Whys

This technique helps to get to the root cause of the problems under consideration and is used in the "analyze" phase of the DMAIC cycle.

In the 5 Whys technique, the question "why" is asked, again and again, finally leading up to the core issue. Although "five" is a rule of thumb, the actual number of questions can be greater or fewer, whatever it takes to gain clarity.

Voice of the Customer

This is the process used to capture the "voice of the customer" or customer feedback by either internal or external means. The technique is aimed at giving the customer the best products and services. It captures the changing needs of the customer through direct and indirect methods. The voice of the customer technique is used in the "define' phase of the DMAIC method, usually to further define the problem to be addressed.

The 5S System

This technique has its roots in the Japanese principle of workplace energies. The 5S System is aimed at removing waste and eliminating bottlenecks from inefficient tools, equipment, or resources in the workplace. The five steps used are Seiri (Sort), Seiton (Set In Order), Seiso (Shine), Seiketsu (Standardize), and Shitsuke (Sustain).

Kaizen (Continuous Improvement)

The Kaizen technique is a powerful strategy that powers a continuous engine for business improvement. It is the practice continuously monitoring, identifying, and executing improvements. This is a particularly useful practice for the manufacturing sector. Collective and ongoing improvements ensure a reduction in waste, as well as immediate change whenever the smallest inefficiency is observed.

Benchmarking

Benchmarking is the technique that employs a set standard of measurement. It involves making comparisons with other businesses to gain an independent appraisal of the given situation. Benchmarking may involve comparing important processes or departments within a business (internal benchmarking), comparing similar work areas or functions with industry leaders (functional benchmarking), or comparing similar products and services with that of competitors (competitive benchmarking).

Poka-yoke (Mistake Proofing)

This technique's name comes from the Japanese phrase meaning "to avoid errors," and entails preventing the chance of mistakes from occurring. In the poka-yoke technique, employees spot and remove inefficiencies and human errors during the manufacturing process.

Value Stream Mapping

The value stream mapping technique charts the current flow of materials and information to design a future project. The objective is to remove waste and inefficiencies in the value stream and create leaner operations. It identifies seven different types of waste and three types of waste removal operations.

Cause and Effect Analysis
Flow Chart
Pareto Chart
Histogram
Check Sheet
Scatter Plot
Control Chart

The Six Sigma training levels conform to specified training requirements, education criteria, job standards, and eligibility.

White Belt

This is the simplest stage, where:

Any newcomer can join.
People work with teams on problem-solving projects.
The participant is required to understand the basic Six Sigma concepts.

Yellow Belt

Here, the participant:

Takes part as a project team member.
Reviews process improvements.
Gains understanding of the various methodologies, and DMAIC.

Green level

This level of expertise requires the following criteria:

Minimum of three years of full-time employment.
Understand the tools and methodologies used for problem-solving.
Hands-on experience on projects involving some level of business transformation.
Guidance for Black Belt projects in data collection and analysis.
Lead Green Belt projects or teams.

Black Level

This level includes the following:

Minimum of three years of full-time employment
Work experience in a core knowledge area
Proof of completion of a minimum of two Six Sigma projects
Demonstration of expertise at applying multivariate metrics to diverse business change settings
Leading diverse teams in problem-solving projects.
Training and coaching project teams.

Master Black Belt

To reach this level, a candidate must:

Be in possession of a Black Belt certification
Have a minimum of five years of full-time employment, or Proof of completion of a minimum of 10 Six Sigma projects
A proven work portfolio, with individual specific requirements, as given here, for instance.
Have coached and trained Green Belts and Black Belts.
Develop key metrics and strategies.
Have worked as an organization's Six Sigma technologist and internal business transformation advisor.

Boost your career path as a skilled quality management expert with our Lean Six Sigma Expert Training aligned with the LSS-Green Belt and Black Belt certification from IASSC. Contact us and get ahead in your career right away!

Six Sigma certification is much like the certification system followed in martial arts, where a wannabe Six Sigma professional begins with the White Belt and upskills his way up to become the master of the pack with the Master Black Belt; or take an integrated certification offered by some institutes.

Fig: The five-tiered levels of Six Sigma Certification

Six Sigma is a great way to climb up the career ladder with cool job titles and to match salary prospects. Companies that routinely hire candidates to fill Sigma Six positions include 3M, Abbott Laboratories, General Electric, The Hershey Company, IBM, Honeywell, Newell Rubbermaid, Siemens, and Wells Fargo.

There are several career choices for Six Sigma professionals as manufacturing engineers, compliance engineers, and operating system specialists.

Additionally, there are career opportunities with the following titles, although the precise nomenclature can vary from company to company:

Six Sigma Analyst
Six Sigma Black Belt
Six Sigma Consultant
Director of Operational Excellence
Functional Project Lead
Senior Project Manager
Six Sigma Projects Manager
Business Process Manager
Lead Analyst/Project Manager

In terms of salary, according to Glassdoor, a Six Sigma Green Belt certified can expect an average yearly salary of $68,840 per year.

Understanding the Management Philosophy of Your Organization, selecting between Six Sigma and Lean Six Sigma, determining which Level Suits You, learning about the Tests Associated with it, Enrolling in a Training Course, and obtaining Your Certification are the steps to obtaining Six Sigma Certification.

2. What Does Six Sigma Mean?

Six Sigma is a quality improvement methodology for businesses that counts the number of flaws in a process and aims to systematically fix them. Businesses utilize it to get rid of flaws and enhance any of their procedures in an effort to increase earnings.

3. What Is the Difference Between Six Sigma and Lean Six Sigma?

Lean and Six Sigma vary primarily in that Lean frequently affects all aspects of an organization rather than being solely focused on production. These two strategies are combined by Lean Six Sigma to produce a potent toolkit for dealing with waste reduction.

4. What Are the Steps of Six Sigma?

Six Sigma's five steps adhere to a methodology known to business insiders as DMAIC. The words "define, measure, analyze, enhance, and control" are all spelled out in this acronym.

5. What is Lean Six Sigma?

Lean Six Sigma is a method for improving performance by systematically removing waste and reducing variation that relies on a collaborative team effort. Increased performance and decreased process variation contribute to defect reduction and improvements in profits, employee morale, and product or service quality.

6. What is continuous improvement?

Continuous improvement (also known as "rapid improvement") is a Lean improvement technique that aids in workflow optimization. The Lean method of working allows for efficient workflows that save time and money, allowing you to cut down on wasted time and effort.

7. What is Lean Six Sigma Yellow Belt?

A Certified Lean Six Sigma Yellow Belt from the Council for Six Sigma Certification (CSSC) is someone who has a basic understanding of Six Sigma but does not lead projects on their own. They are frequently in charge of creating process maps to support Six Sigma projects.

8. What is Lean Six Sigma Green Belt?

Six Sigma Green Belt is a certification course that provides you with hands-on experience with over 100 tools and techniques. These techniques are required for participation in DMAIC improvement projects. DMAIC is an acronym that stands for Define, Measure, Analyze, Improve, and Control.

9. What is Lean Six Sigma Black Belt?

A Lean Six Sigma Black Belt has a thorough understanding of all aspects of the Lean Six Sigma Method, including a high level of competence in the Define, Measure, Analyze, Improve, and Control (DMAIC) phases as defined by the IASSC.

So whether you are a graduate in any stream, an engineer, or an MBA professional, if you want to enhance your career prospects and salary gains, then make sure to get certified in Six Sigma courses. Begin with a Green Belt and climb your way up to Master Black belt to command your salary. As a fresher, you can start learning Six Sigma principles by enrolling into Simplilearn's Green Belt certificate program, and then avail the higher certificate levels as you gain work and project experience.