Six Sigma is a leadership strategy guided by evidence utilizing particular methods and methodologies that contribute to fact-based decision-making. The DMAIC (Define–Measure–Analyze–Improve–Control) approach to addressing the fundamental issue of reducing procedure variability is something which enterprises across industry sectors use. Most importantly, companies use Six Sigma Methods to reduce defects and variation.
According to the report, the use of the Six Sigma technique resulted in the delicate grinding process being reduced from 16.6% to 1.19%. The DMAIC approach created a substantial financial effect on the company’s sustainability in terms of reducing the cost of waste, saved person-hour on rework, and led to improved production. In turn, the project announced a savings of approximately US$ 2.4 million per annum.
Six Sigma Methods to Reduce Defects
Research
In the Six Sigma methods, the research team collaborates with other critical teams within the organization to collect data inputs across departments. Upon data collection, the data is fed into relevant tools such as Minitab to find statistical inputs which clearly shows the variance and where exactly waste is happening.
After getting the reports, the study of literature will be performed to understand the historical experience of other change efforts within the organization for process improvement.
Literature Review
Sigma is a letter in the Greek alphabet, which has been the mathematical symbol and metric of difference in operation. The calculation sigma scale is precisely associated with such features as per-unit faults, parts-per-million faults, and the rate of failure. Six Sigma is equivalent to 3.4 odds of defects per million. To raise a process’s sigma number, the company has to decrease the amount of variance to make sure the process is managed accordingly.
Six Sigma is essentially based on five stages, namely Identifying, Evaluating, Assessing, Enhancing, Monitor (DMAIC), achieving the organizational targets by increasing process efficiency, and meeting high-quality thresholds by removing the root cause(s) of defects and reducing process and product variability.
In addition to understanding the consumer wants and expectations, Define Step is associated with identifying the issue and the scale of the project. Data can be obtained and expanded when in the Measure step, and the primary process characteristics can be calculated. The root cause of this problem can be determined in the Examine process; the tests and the mathematical methodology can be carried out. The Improve Process is committed to creating the potential for development and choosing the most desirable for minimizing/removing defects. The control phase works on ensuring the modifications are retained and stopping process output from returning.
Improve Phase
The purpose of the Improve process is to design, test, and enforce strategies that fix root causes and use data to analyze the system as well as the plans that have been implemented. This Step’s principal production includes:
- Planned and checked interventions removing or minimizing the impacts of the root cause(s) identified;
- “Before” and “after” data review, showing the original distance change gained;
- A summary of the synthetic strategy and practical execution
Regression Analysis
The regression study will be carried out after defining the potential causes of the primary defects in the evaluating process
Identify the connection between certain factors and the number of pieces refused.
A total number of 20 samples is chosen from the available statistical knowledge on the manufacturing processes as the sufficient sample number to be checked.
Conclusion
The Six Sigma method is a project-driven organization structure based on the theories and processes for reducing the defects of a given function. To learn more about various Six Sigma techniques and how you benefit from them, you should consider pursuing popular quality management certification courses from an accredited training provider.
Some of the popular Quality Management Certification courses that individuals and enterprise team members can take up are:
Lean Six Sigma Green Belt Online Course
Six Sigma Black Belt Certification
