Six Sigma Methodology Steps, Questions

What is Six Sigma?

Six Sigma is a set of techniques and tools for process improvement. It was developed by Motorola in 1986 and has become a global standard for improving manufacturing and business processes by reducing errors and increasing quality.

Brief Historical Overview

The concept of Six Sigma was introduced by Bill Smith at Motorola in 1986. The methodology was developed to improve manufacturing processes and eliminate defects. In the 1990s, General Electric adopted Six Sigma, which significantly increased its popularity and application across various industries.

Six Sigma Tools + Techniques

6 Sigma Worksheet Example

Describe Each Six Sigma Step

Six Sigma follows the DMAIC methodology, which stands for Define, Measure, Analyze, Improve, and Control.

Define

Identify the problem and define the project goals and customer (internal and external) requirements.

How to Use the Define Step

Define the project scope and objectives.
Identify the stakeholders and their requirements.
Create a project charter.
Map the process at a high level.
Set a timeline and resources.

5 Questions for the Define Step

What problem are we trying to solve?
Who are the customers and what are their needs?
What is the scope of the project?
What are the project objectives?
What resources are required for the project?

Measure

Quantify the problem by collecting data and establishing baseline measurements.

How to Use the Measure Step

Identify key performance indicators (KPIs).
Develop a data collection plan.
Collect data and measure current performance.
Validate the measurement system.
Establish baseline performance levels.

5 Questions for the Measure Step

What data do we need to collect?
How will we collect the data?
What are the key performance indicators?
Is our measurement system reliable?
What is the baseline performance level?

Analyze

Identify the root causes of the problem by analyzing the data.

How to Use the Analyze Step

Use statistical tools to analyze data.
Identify patterns and trends.
Determine root causes of defects or issues.
Validate root causes with data.
Prioritize root causes based on impact.

5 Questions for the Analyze Step

What patterns or trends are in the data?
What are the potential root causes of the problem?
How can we validate the root causes?
What is the impact of each root cause?
Which root causes should we prioritize?

Improve

Develop and implement solutions to address the root causes of the problem.

How to Use the Improve Step

Brainstorm potential solutions.
Develop and test solutions.
Implement the most effective solutions.
Monitor the improvements.
Document the changes and results.

5 Questions for the Improve Step

What solutions can we develop to address the root causes?
How will we test the solutions?
What is the best way to implement the solutions?
How will we monitor the improvements?
How will we document the changes and results?

Control

Maintain the improvements by controlling the processes and ensuring consistent performance.

How to Use the Control Step

Develop a control plan.
Implement process controls and monitoring systems.
Train employees on new processes.
Regularly review performance data.
Make adjustments as needed to maintain improvements.

5 Questions for the Control Step

What control measures do we need to implement?
How will we monitor the process going forward?
What training is required for employees?
How often will we review performance data?
What adjustments might be necessary to maintain improvements?

Strengths and Weaknesses of Six Sigma

Strengths

Data-driven decision making.
Focus on customer requirements.
Structured problem-solving approach.
Improves process efficiency and quality.
Can lead to significant cost savings.

Weaknesses

Can be resource-intensive.
Requires significant training and expertise.
May be too rigid for some organizations.
Focuses primarily on incremental improvements.
Implementation can be time-consuming.

When to Use Six Sigma? Areas of Application

Manufacturing processes.
Service industries (e.g., healthcare, finance).
Supply chain management.
Customer service and satisfaction improvement.
Any process requiring reduction in variability and defects.