Intro to SIx Sigma

Where did Lean originate?

Japan (Toyota)

Who came up with Six Sigma?

Bill Smith from Motorola

What is Six Sigma?

A management system for running business on a day to day business

What is the main focus of Six Sigma?

Reducing defects

What are the roles in Six Sigma?

Executive team, Champions, Green belts, Black belts, Master black belts

What are the roles of the Executive Team?

1. Have a Lean - Six Sigma vision

2. Mandate improvement

3. Identify champions

4. Review all projects

What are the roles of champions?

1. Communicate the vision of Executive Team

2. Select projects

3. Select candidates for training

4. Review projects weekly

   1. Remove barriers and supply resources

What are the roles of Green Belts?

1. Lead small LSS projects

2. Participate as a team member on larger projects

3. Communicate Six Sigma to ppers

4. Carry out technical tasks; collect and analyze data

5. Work to solve problems

6. Enter data & perform analysis

What are the roles of Black Belts?

1. Manage and facilitate LSS project teams

2. Discover opportunities for new LSS projects

3. Mentor Green Belts and team members

4. Train team members

5. Influence others in the organization

6. Perform more complex data analysis

What are the roles of Master Black Belts?

1. Lead transformation efforts

2. Provide statistical expertise

3. Coach, mentor, and teach belts

4. Supervise and mentor multiple projects

5. Track ROI

What is the Motorola Shift?

1.5 sigma

What is the defect rate for a Six Sigma process?

3.4 DPMO (Defects Per Million Opportunities)

What does Lean do?

Reduce waste by streamlining processes

What does Six Sigma do?

Reduces defects by solving problems

What is DMAIC?

Define, Measure, Analyze, Implement, Control

What does DMAIC do?

A problem solving approach used to identify and verify root causes of defects and ways to eliminate them

What are the criteria for selecting a good LSS project?

1. Choose project opportunities

2. Has Xs that can be altered

3. An obvious problem with no clear solution

4. Improve revenue, cost, or efficiency

5. Measurable and collectable data

6. Support of senior leadership

7. Linked to the organization’s strategic objectives

What does the project charter do?

Summarize the project plan

What does the project charter do?

Who, What, When, Why

What are the elements of the project charter?

1. Problem statement

2. Mission statement

3. Scope

4. Key assumptions and constraints

5. Risks and risk responses

6. Budget

7. Roles and responsibilities 

8. Milestones and deliverables

9. Success criteria

10. Approvals

What tool can be used to create the project charter?

A3

What is the mission statement?

Outcome which we will try to achieve with the project

What QUANTITATIVE details are in the mission statement?

1. Expected improvement (In units, %, etc.)

2. Target completion date

3. Expected cost savings (i.e. annual $)

Who are stakeholders?

People who will be affected by the project but are not directly involved with doing project work

Examples of stakeholders:

Managers, suppliers, clients

What are the 3 types of customers?

External, internal, shareholders

What is a CTQ?

What the client expects of a product or serviceW

What are characteristics of a good CTQ?

1. Can be measured

2. A specification can be set

What is the relationship between voice of the customer, critical to quality, and project metrics?

VOC leads to CTQ which leads to Y

What are examples of VOCs?

1. I want my pizza delivered hot

2. The yarn must be strong

3. Your invoice must reach me by the 10th of each month

What are some examples of CTQs?

1. 90% of pizza should be delivered within 15 minutes of leaving the store

2. The shipping department must ship documents out by 6pm each day

3. The yarn break strength must be greater than 25 ft-lbs

What are internal customers?

Stakeholders, project owners, management team

What are external customers?

End user of the product/service

What are some readily available sources of VOCs?

1. Warranty requests

2. Complaints

3. Returns

How else can companies collect VOCs?

Mailed/electronic questionnaire, interview, phone call, focus groups

How can affinity diagrams be useful?

Convert VOCs into CTQs

What are the 3 aspects of satisfaction in the Kano model?

1. Must be (basics, necessities)

2. More is better

3. Delighters (beyond expectations)

What is Rolled Throuhput Yield?

Probability that a unit passes through an entire multi-step process without any defects

How is Rolled Throughput Yield calculated?

Multiply the yield of each step