Manufacturing is tough enough without adding standard deviation into the mix. Alas, and alack, that’s exactly what Six Sigma in manufacturing does — in the most basic terms. However, that doesn’t have to be a bottleneck if you want to learn everything about Six Sigma, warts and all.
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Adding Six Sigma manufacturing to your processes can feel as daunting as paddling a boat using a spoon. In this article, we’ll break things down into bite-sized pieces.
Table of Contents
- What Is Six Sigma?
- Six Sigma Methodologies
- Implementation Steps
- Examples In Manufacturing
- Primary Benefits
- Six Sigma Certification
- Barriers to Implementation
What Is Six Sigma?
Six Sigma is a process improvement and quality control system in manufacturing operations. It uses standard deviation based on the bell curve to determine the number of acceptable defects in a million manufacturing steps.
History and Etymology
It was developed by Bill Smith, an engineer at Motorola, in 1986. Your company can only achieve Six Sigma nirvana if you make just 3.4 mistakes in one million steps. That adds up to a pretty minuscule percentage — 99.99966%, to be exact.
However, it has changed over generations. Currently, there’s no universally accepted “Bible” of Six Sigma. Bill Smith’s former colleague said in 2017, “ Six Sigma isn’t absolute: it’s a vision.”
Six Sigma Methodologies
It’s a truth universally acknowledged that a company in want of a Six Sigma system needs to understand its methodologies. There are a few widely accepted methodologies:
- Define, Measure, Analyze, Improve and Control (DMAIC)
- Design for Six Sigma (DFSS)
- Root Cause Analysis
The DMAIC Method
DMAIC is a five-step process designed to shape and change your organization’s entire approach to improvement. It works like PEMDAS, so you’ve got to follow the steps in order. Here are the steps in order of implementation:
- Define: Every masterpiece needs a blueprint. In this process stage, you must set objectives and develop concrete terms.
- Measure: Just like any SMART goal, you’ve got to be able to measure what you need to accomplish. It’s a data-driven step that allows you to assess process capabilities.
- Analyze: The primary purpose of this stage is to identify the root causes that will help improve processes. Select the top root causes and apply statistical tests to determine their effect on operations.
- Improve: Now that you know the problem, finding the solution is possible. Identify ways to fix the problem’s root cause using tools like Design of Experiments.
- Control: Sustainability is a key factor when making any process change. You want to make sure your changes have a lasting impact. Here you’ll create a control plan and spell out procedures and processes.
Design for Six Sigma
DFSS is much like a Nolan film — it leaves plenty up to interpretation. It’s often used interchangeably with DMADV: define, measure, analyze, design and verify. However, another approach is to use IDOV: identify, design, optimize and verify.
The main difference between the DFSS and DMAIC methods is that the former’s primary purpose is to create a new process, while the latter skews toward continuous improvement.
Root Cause Analysis
Much like the approach of a psychiatrist, root cause analysis goes beyond the symptoms to unearth the core of problems. Course-correcting starts with discovering why the problems occur instead of fixing surface-level issues.
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Implementation Steps
Translating a Six Sigma methodology into reality in your manufacturing process requires a systematic approach. Stick to the following steps to implement Six Sigma without a hitch.
Identify a Pilot Project
Go big or go home is a metaphor best left for sports movies. Start small with a pilot project where you identify an inefficient process. Understand what’s happening in production and determine what needs to improve.
Develop a Plan
Next, you’ll need to figure out how to combat inefficiencies. You can use the five whys to help analyze the root causes and set up a plan to neutralize them. It may involve structural overhauls and team collaboration.
Teach the Methodology
A clear understanding of Six Sigma methodologies goes a long way toward the long-term adoption of plans and principles. Teach your employees the principles and identify team members who may benefit from certification.
Prioritize Implementation
Initially, you may need extra effort to implement new changes. It’s important to prioritize Six Sigma efforts and ensure activities align with production process improvement.
Create a Benchmarking System
A scientific and data-driven approach is essential to success. Creating a measurement system helps you define a benchmark and make quantitative measurements and decisions.
Evaluate and Improve Processes
Here’s where continuous improvement comes into the picture. Evaluate how well you accomplished your goals and identify areas of improvement using feedback from team members. Continue improving processes by applying the steps above with key insights from past projects.
Examples
Six Sigma in manufacturing isn’t new. Numerous companies across the globe have implemented some form of Six Sigma into their operations. While Motorola might have kicked things off, GE is probably one of the most high-profile examples.
Check out some notable case studies below:
General Electric: CEO Jack Walsh made Six Sigma a part of the corporate culture at GE after widespread doubts about quality. This new system helped identify defects and increase profits.
Motorola: Rising competition from Japanese companies led to Bill Smith systematizing Six Sigma, improving quality management and increasing revenue.
Boeing Airlines: An inability to figure out a defect in their engine fan caused Boeing to implement Six Sigma. It helped pinpoint the exact cause of the electrical problem.
Primary Benefits
If we follow Six Sigma methodology, logic dictates that its benefits must be measurable. Change can be scary (just like learning about Six Sigma), but it can also be rewarding. Here’s how it can help boost your manufacturing operations.
Increase Productivity
It doesn’t take a Six Sigma expert to tell you that increased productivity is always good for business. Companies already use plenty of KPIs to determine whether production is cutting the mustard. View progress through predefined metrics, all backed by data measurements, to target problem areas and boost productivity.
Improve Throughput
Many band-aid solutions fix the symptoms but not the issue’s core. Pinpointing and removing root cause problems improves throughput. Instead of wasting time with trial and error when implementing new processes, you can access data analysis to make changes based on hard, cold facts.
Minimize Damage Control
Data collection and insights give you greater visibility into production. Armed with this knowledge, you can quickly identify or even preempt exceptions and defects caused by faulty machinery, unclear use case practices and unscheduled downtime.
Reduce Operating Costs
Streamlined production saves time and money. More significant insights into operations help cut down labor costs, maintenance costs and raw materials.
Six Sigma Certification
While scrolling through LinkedIn, you might see terms like Six Sigma yellow or black belt flashing up frequently. Like karate, Six Sigma has various levels of certification: white, yellow, green and black.
White Belt
If you’ve made it this far in the article, you’re unofficially a white belt! No formal training or certification is required to become a white belt. A rudimentary understanding of the fundamentals and concepts is all you need to implement this framework into projects and problem-solving tasks.
Yellow Belt
The next level is a basic course that provides the foundational knowledge of Six Sigma tools, methodologies and improvement procedures. Yellow belt certification enables you to support project teams and managers with higher belt certification.
Green Belt
This intermediate certification covers advanced analysis and provides the tools to create control charts and process maps. Once you pass, you’ll be able to lead projects.
Black Belt
The Mecca of Six Sigma certification, a black belt, helps students acquire advanced knowledge of lean six sigma strategies, how to drive organization-wide change and real-world experience. In addition to leading projects and managing operations, they help train and mentor yellow and green belt holders.
Implementation Challenges
With yin also comes yang. The perks and benefits of Six Sigma implementation don’t come without challenges. It’s unrealistic to expect that adopting Six Sigma will be as easy as Arya Stark killing the Night King. Read on to discover some common barriers to implementation.
Inconsistency in Definitions and Approaches
There are multiple methodologies and even definitions of Six Sigma. There’s no universal guidepost or set formulae, with plenty of leeway for deviations. Confusion and incompatibility with data-driven analysis may lead to poor identification of problem areas.
Lack of Resources
Rome wasn’t built in a day. Likewise, implementing a new system company-wide takes enormous time and resources. Smaller firms may not have the resources to upend operations and spend time on training and certifications.
Internal Resistance
“If it ain’t broke” is the approach many employees may take when faced with the prospect of changing processes. More stress, added workload and a lack of interest may affect employee resistance.
Some employees, even if they’re open to learning, may also need additional educational courses to pick up Six Sigma methodologies quickly.
Dependence on Statistics
It’s in the name. Six Sigma is a highly quantitative process backed by methods and tools. Depending solely on rigid technical rationality without consideration of intersectional factors can hamper workforce development, cultural awareness and organizational adaptability.
1.5 Sigma Shift
The 1.5 sigma shift accounts for lack of performance in long-term versus short-term processes. However, statisticians doubt its arbitrary nature and the translation of Six Sigma scoring into normal distribution probabilities.
Overuse of Consultants
You can’t search for Six Sigma without advertisements for certifications and black belt training popping up. A reliance on hiring certified black belts as change agents and an influx of consulting from outside sources unfamiliar with your industry may not be beneficial.
Next Steps
Implementing Six Sigma in your manufacturing operations can be beautiful, like the perfect pass from a quarterback. However, like with football, plenty of variables can go awry. Being mindful of the barriers in such a data-driven process is essential.
An accurate idea of your company’s software needs helps too. Consider whether your current manufacturing solution will support your efforts. If not, our free requirements template will help lay the foundation for a smooth software comparison.
What are some ways Six Sigma could benefit your manufacturing operations? Let us know in the comments below!