SIX SIGMA

PREPARED BY : [Link] S RASKAR

LEAN SIX SIGMA

LEAN- FOCUSES ON WASTE REDUCTION

BY STREAMLINING THE PROCESS.

SIX SIGMA- FOCUSES ON PREVENTING

DEFECTS THROUGH PROBLEM SOLVING.

IT IS DATA DRIVEN APPROACH USED IN

PROJECT MANAGEMENT TO ACHIEVE THE
PROCESS IMPROVEMENT & MINIMIZE
DEFECTS.
LEAN SIX SIGMA
 GOALS ARE ACHIVED THROUGH TWO PROLONGED APPROACH

A) IDENTIFICATION OF THE PROBLEM-

WHERE DOES FUNCTION DEVIATE FROM
“WHAT SHOULD BE” AND “WHAT IS” ?

B) SOLVING THE PROBLEM- CHANGING THE

STATE OF FUNCTION FROM “WHAT IS” TO
“WHAT SHOULD BE” ? ENSURING CHANGE IS
IMPLEMENTED TO ACHIEVING THE GOALS.
5 KEY PRINCIPLES OF THE SIX SIGMA

5-KEY PRINCIPLES BELOW:

1. CUSTOMER FOCUS.
2. MEASURE THE VALUE OF STREAM
AND FIND YOUR PROBLEM.
3. GET RID OF YOUR JUNK.
4. KEEP THE BALL ROLLING.
5. ENSURE FLEXIBLE AND RESPONSIBLE
EXOSYSTEM.
 SIX SIGMA METHODOLOGY
THERE ARE TWO METHODOLOGIES:
1. DMAIC : (DEFINE – MEASURE – ANALYZE – IMPROVE – CONTROL.)
2. DMADV: (DEFINE – MEASURE – ANALYZE –DISIGN– VERIFY.)

DMAIC DMADV
 DIFFERENCE BETWEEN DMAIC & DMADV
COPARISON FOR DMAIC DMADV

MEANING TO IMPROVE THE EXISTING PROCESS TO DESIGN NEW OR EXISTING PROCESS.

TYPES OF PROCESS REACTIVE PROCESS PROACTIVE PROCESS

FOCUSES ON PROCESS FOCUSED CUSTOMER-FOCUSED

TEAM REQUIRED SMALL TEAM LARGE TEAM

TIME HORIZON SHORT TO MEDIUM TERM LONG TERM

USED WHEN CONTINUOUS IMPROVEMENT REQUIRED REENGINEERING IS REQUIRED

APPROACH CORRECTIVE PREVENTIVE

TOOLS USED STATISTICAL & QUANTITATIVE TOOLS QUALITATIVE TOOLS

IMPLEMENTED WHEN INCREMENTAL CHANGE IS NEEDED EVOLUTIONARY CHANGE IS NEEDED

DMAIC IS A DATA DRIVEN METHOD USED TO IMPROVE EXISTING
PROCESSES, PRODUCTS AND SERVICES.
DMAIC TOOLS FOR IMPROVE THE PROCESS, PRODUCTS AND SERVICES.
DMAIC TOOLS FOR DEFINE PHASE

1. PROJECT IDENTIFICATION/SELECTION :

IMPLEMENTATION OF PROJECTS – USED WHEN

SOLUTIONS ARE OBVIOUS & ONLY EXECUTION IS REQUIRED.
LEAN PROJECTS – USED WHEN DRIVERS OF PERFORMANCE
ARE EASY TO IDENTIFY.
SIX SIGMA (DMAIC) PROJECTS – USED WHEN DRIVERS OF
PERFORMANCE ARE UNKNOWN & MUST BE ANALYSED.
SIX SIGMA (DMADV) PROJECTS – USED WHEN NEW
PRODUCTS, SERVICES AND PROCESSES ARE REQUIRED OR
WHEN EXISTING SERVICES & PROCESSES MUST BE
REDESIGNED.
DMAIC TOOLS FOR DEFINE PHASE

2. PROJECT CHARTER:
PROJECT CHARTER IS A FOUNDATIONAL DOCUMENT THAT
OUTLINES THE PURPOSE, SCOPE, OBJECTIVES AND KEY
STAKEHOLDERS OF THE PROJECT. IT SERVES AS A ROADMAP,
PROVIDING CLARITY AND DIRECTION FROM THE VERY
BEGINNING.

ESTABLISHES PURPOSE: IT ENSURES THAT ALL TEAM

MEMBERS ARE ALIGNED WITH ITS GOALS & OBJECTIVES.

DEFINE SCOPE: IT CLEARLY OUTLINE THE BOUNDARIES OF

THE PROJECT, HELPING THE TEAM STAY FOCUSSED ON
ADDRESSING THE RELEVENT ISSUES.

IDENTIFIES STAKEHOLDERS: THE CHARTER LISTS KEY

STAKEHOLDERS, ENSURING THAT THEIR NEEDS AND
EXPECTATIONS ARE CONSIDERED THROUGHOUT THE
PROJECTS LIFECYCLE.
DMAIC TOOLS FOR DEFINE PHASE

[Link] OF CUSTOMER (VOC):

UNDERSTANDING THE CUSTOMERS NEEDS AND
[Link] ANALYSIS TOOLS SUCH AS SURVEYS,
INTERVIEWS & DIRECT FEEDBACK COLLECTIONS, HELP
GATHER CUSTOMER INSIGHTS AND TRANSLATE THEM INTO
ACTIONABLE PROJECT GOALS.
VOC REVEALS THAT SPPED & ACCURACY.
DMAIC TOOLS FOR DEFINE PHASE

4. SIPOC:
THE SIPOC (SUPPLIERS, INPUTS, PROCESS, OUTPUTS,
CUSTOMERS) DIAGRAM IS A VISUAL REPRESENTATION THAT
PROVIDES AN OVERVIEW OF THE HIGH LEVEL PROCESS FLOW,
INCLUDING ITS IN[PUTS, OUTPUTS AND KEY STAKEHOLDERS.
DMAIC TOOLS FOR DEFINE PHASE

5. AFFINITY DIAGRAM:
IT IS A BRAINSTORMING TOOL, DEVELOPED BY “JIRO
KAWAKITA” IN 1960. OR “KJ METHOD”.

IT IS A WAY OF TAKING FACTS, IDEAS OR DATA ON CERTAIN

THEME AND ORGANISING IT INTO GROUP OF CLUSTERS. IT
CAN BE THE 1ST STEP TOWARDS A CAUSE-AND-EFFECT
ANALYSIS USING AN FISHBONE DIAGRAM.
DMAIC TOOLS FOR MEASURE PHASE

1. PROCESS MAP / VALUE STREAM MAP:

PROCESS MAPPING TOOLS LIKE FLOWCHARTS AND VALUE
STREAM MAPS PROVIDE A VISUAL REPRESENTATION OF THE
PROCESS. THEY HELP IN UNDERSTANDING THE SEQUENCE OF
STEPS, INPUTS AND OUTPUTS IN THE PROCESS.

IT HELPS:
VISUAL CLARITY:-CLEAR VISUAL REPRESENTATION OF THE PROCESS,
MAKING IT EASIER IDENTIFICATION OF THE BOTTLENECKS.

IDENTIFY HANDOFFS:-HIGHLIGHTS POINTS WHERE WORK IS

HANDED OFF BETWEEN INDIVIDUALS OR DEPARTMENTS, WHICH CAN
BE SOURCES OF DELAYS.

ROOT CAUSE ANALYSIS:-FACILITATES THE IDENTIFICATION OF

AREAS WITHIN THE PROCESS THAT MAY NEED IMPROVEMENT.

PROCESS MAP PROMOTE THE CONTINUOUS IMPROVEMENT.

DMAIC TOOLS FOR MEASURE PHASE

2. DATA COLLECTION:
DATA COLLECTION PLAN IS STRUCTURED DOCUMENT THAT
OUTLINES WHAT DATA NEEDS TO BE COLLECTED, HOW IT BE
COLLECTED, WHEN IT BE COLLECTED AND WHO WILL BE
COLLECTED.
DATA COLLECTION PLAN PROVIDE CLUES TO ROOT CAUSE.
THE AIM OF DATA COLLECTION PLAN IS ACHIEVE
IMPROVEMENT BY REDUCING DEFECTS.

TYPES OF DATA:
[Link] & UNSTRUCTURED DATA.
[Link] & QUANTITATIVE DATA.
[Link] & DISCRETE DATA.
DMAIC TOOLS FOR MEASURE PHASE
 DMAIC TOOLS FOR MEASURE PHASE

3. SAMPLING TECHNIQUE:
Sampling
SAMPLE IS A SMALL GROUP OF MEMBERS SELECTED FROM
POPULATION TO REPRESENT THE POPULATION.

Probability Non-Probability USE SAMPLING TECHNIQUES FOR GETTING THE DATA FROM
Sample Sample THE ENTIRE POPULATION WITHIN TIME.

Random Judgmental TYPES OF SAMPLING APPROACHES:

[Link] SAMPLING.
[Link] RANDOM SAMPLING.
Stratified Convenience [Link] SAMPLING.
[Link]/SUBGROUP SAMPLING.

Systematic Quota

Cluster Snowball
 DMAIC TOOLS FOR MEASURE PHASE

MSA 4. MEASUREMENT SYSTEM ANALYSIS (MSA):

MSA IS A TOOL FOR ANALYZING THE VARIATION PRESENT IN
EACH INSPECTION, MEASUREMENT AND TEST EQUIPMENT
Measurement TYPE.
Process Variation IT IS USED TO ASSESS THE QUALITY OF THE MEASUREMENT
variation
SYSTEM.

Accuracy Precision

Repeatability Reproducibility

Bias Linearity Stability

 DMAIC TOOLS FOR ANALYZE PHASE
1. CAUSE & EFFECT DIAGRAM (FISHBONE DIAGRAM):
ALSO KNOWN AS FISHBONE OR ISHIKAWA DIAGRAM, THIS TOOL HELPS VISUALIZE POTENTIAL CAUSES OF A
PROBLEM.
IT HELPS TO IDENTIFY THE ROOT CAUSES OF PROBLEM.

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ISSUE: MANAGEMENT MAN MACHINE MEASUREMENT MATERIAL METHOD EFFECT:

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Fishbone Diagram
 DMAIC TOOLS FOR ANALYZE PHASE
2. 5-WHY ANALYSIS :
IT IS DEVELOPED BY JAPANESE PROFFESSOR KAORU ISHIKAWA.
IT INVOLVES REPEATEDLY ASKING “WHY”? TO DIG DEEPER INTO THE ROOT CAUSE OF THE PROBLEM. BY ASKING
“WHY” ? 5 TIMES, IT AIMS TO UNCOVER THE UNDERLAYING ISSUES.
 DMAIC TOOLS FOR ANALYZE PHASE
3. PARETO DIAGRAM:
PARETO CHART USE TO IDENTIFY WHICH AREAS NEED THE MOST IMPROVEMENT.
IT IS ALSO KNOWN AS 80/20 RULE, THE PRINCIPLE STATES THAT 80% OF THE EFFECTS COME FROM JUST 20% OF THE
CAUSES.
 DMAIC TOOLS FOR ANALYZE PHASE
3. SCATTER DIAGRAM:
SCATTER GRAPH IS USED TO FIND OUT THE RELATION BETWEEN THE TWO VARIABLES.
IT IS USED IN PROBLEM SOLVING TO ESTABLISH A ROOT CAUSE.
DMAIC TOOLS FOR IMPROVE PHASE

1. BRAINSTORMING:
BRAINSTORMING IS A CREATIVE PROBLEM-SOLVING
TECHNIQUE THAT INVOLVES GENERATING A WIDE RANGE
OF IDEAS AND POENTIAL SOLUTIONS.

IDEA GENERATIONS- ENCOURAGE THE GENERATION OF

IDEAS AND SOLUTION FROM TEAM MEMBERS.

PROMOTE TEAMWORK- FOSTERS COLLABORATION AND

PARTICIPATION ALLOWING FOR VARIETY OF PERSPECTIVES.
 DMAIC TOOLS FOR IMPROVE PHASE

2. FMEA (FAILURE MODE EFFECT

ANALYSIS):
IT IS STRUCTRED APPROACH TO IDENTIFY
FAILURES THAT MAY EXIST WITHIN PRODUCTS
AND PROCESS.
Mode of Cause Effects Frequency Severity Detection RPN
Failure FMEA PROCESS:
Hollowness Adhesive Dado - IDENTIFY THE MODE OF FAILURE.
3 5 5 75
observed in application rework - IDENTIFY THE ROOT CUASE OF FAILURE.
dado tile. thickness must. - IDENTIFY POTENTIAL EFFECTS OF FAILURE.
not as per - RATE THE FREQUENCY OF OCCURENCE OF
std. ROOT CAUSE.
One side Dado 5 7 5 175 - RATE THE SEVERITY OF EFFECT.
adhesive rework - RATE THE DETECTABILITY OF EACH MODE.
application must. - CALCULATE THE RISK PRIORITY NUMBER
observed (RPN).
- RPN= FREUENCY * SEVERITY * DETECTION
- AFTER THAT RPN INDICATES THAT WHICH
ONE SHOULD BE GIVE THE PRIORITY FOR
ACTION.
CONCLUSION:
RPN OF 2ND CUASE IS HIGH, SO IT SHOULD GIVE THE PRIORITY FOR ACTION.
DMAIC TOOLS FOR IMPROVE PHASE

3. POKA-YOKE:
IT IS A TOOL USED TO PREVENT OR DETECT MISTAKES IN A
PROCESS.
PRIMARY AIM TO ACHIEVE ZERO DEFECTS BY ELIMINATING
HUMAN ERRORS.
IT PLAYS IMPORTANT ROLE IN IMPROVING PRODUCTIVITY
WITH NO REWORK.

EXAMPLE:-
DMAIC TOOLS FOR IMPROVE PHASE

4. PILOT TESTING:
IT IS A SMALL SCALE TEST OF A NEW
PROCESS, SYSTEM IN A CONTROLLED
ENVIRONMENT BEFORE IMPLEMENTING IT
ON LARGER SCALE.

OBJECTIVES OF PILOT TESTING:

- MINIMIZES RISK.
- SAVE TIME & MONEY.
- GAINS VALUABLE INSIGHTS.
- VALIDATE SYSTEM REQUIREMENTS.
DMAIC TOOLS FOR IMPROVE PHASE

5. KAIZEN (CONTINUOUS IMPROVEMENT):

KAIZEN IS DMAIC TOOL USED FOR
CONTINUOUS IMPROVEMENT IN IMPROVE
PHASE.

IT AIMS TO ELIMINATE WASTE IN ALL SYSTEM

THROUGH IMPROVING STANDARDIZE
ACTIVITIES AND PROCESS.

PRINCIPLES OF KAIZEN-
CONTINUOUS IMPROVEMENT.
EMPLOYEE INVOLVEMENT.
ELIMINATION OF WASTE.

PDCA & 5S STARTEGY USED FOR CONTINUOUS

IMPROVEMENT IN KAIZEN TOOL.
DMAIC TOOLS FOR CONTROL PHASE

1. QUALITY MANAGEMENT OR TQM:

IT IS MANAGEMENT APPROACH DESIGNED TO
HELP COMPANIES CREATE AN ENVIRONMENT
OF CONTINUOUS IMPROVEMENT,
CONSISTENTLY DELIVERING HIGH QUALITY
PRODUCT & SERVICES.
DMAIC TOOLS FOR CONTROL PHASE

2. QM-PROCESS DIAGRAM PDCA :

PDCA CYCLE IS A QUALITY MANAGEMENT
METHODOLOGY THAT CAN HELP TO IDENTIFY & ADDRESS
THE ISSUES, TRACK PERFORMANCE & CONTINUOUSLY
IMPROVE THEIR QMS.

PLAN:- IDENTIFY PROBLEM , SET A GOAL, STARTEGY TO

IMPLEMENT CHANGES & IMPROVEMENT.
DO:- IMPLEMENT THE ACTION PLAN DEVELOPED IN
PREVIOUS STAGE. CHANGES ON SMALL SCALE TO TEST
THEM.
CHECK:- MEASURE THE PROGRESS REGULARLY, EVALUATE
PERFORMANCE AGAINST. MONITOR THE RESULTS OF
CHANGES MADE AT THE DO STEP.
ACT:- MAKE DECISIONS BASED ON THE RESULTS OBTAIN
IN THE CONTROL PHASE.
DMAIC TOOLS FOR CONTROL PHASE

3. STATISTICAL PROCESS CONTROL (SPC):

SPC TOOL IS USE OF STATISTICAL TECHNIQUES
TO CONTROL THE PROCESS OR PRODUCTION
METHOD.

IT IS THE STANDARD METHODOLOGY FOR MEASURING

AND CONTROLLING QUALITY DURING THE
PRODUCTION PROCESS.

THROUGH THE SPC WE WILL FIND OUT WHETHER OUR

PROCESS IS STABLE OR OUT OF CONTROL.

IT HELP TO MEASURE & TRACK THE PROCESS

PERFORMANCE, IDENTIFY PROBLEMS & DETERMINE
CORRECTIVE ACTIONS.

IT IS USED TO MEASURE STABILITY OF THE

PROCESS.
DMAIC TOOLS FOR CONTROL PHASE

4. PROCESS STANDARDIZATION:
IT INVOLVES ESTABLISHING THE UNIFORM PROCEDURES AND
GUIDELINES FOR PERFORMING SPECIFIC TASK & ACTIVITIES.

IT HELPS TO MINIMISE THE VARIATION IN PERFORMANCE , REDUCE

ERRORS AND ENHANCES OVERALL QUALITY CONTROL.

TYPES OF PROCESS STANDARDIZATION:

- DOCUMENT STANDARDIZATION.
- WORKFLOW STABDARDIZATION.
- RESOURCES STANDARDIZATION.
- POLICY STANDARDIZATION.
 DMAIC TOOLS FOR CONTROL PHASE
5. RUN CHART:
RUN CHART IS A LINE CHART OF DATA PLOTTED OVER TIME. IT GRAPHICALLY DEPICTS THE PROCESS PERFORMANCE
IN TIME ORDER.
IT IS ALSO KNOWN AS TREND CHART.
 BENEFITS OF IMPLEMENTING SIX SIGMA

[Link] CUSTOMER SATISFACTION:

- MINIMIZES THE DEFECTS & OPTIMIZES PROCESSES.
- LEADS TO PRODUCT & SERVICES THAT EXCEED CUSTOMER EXPECTATIONS.

[Link] REDUCTION:
- ELIMINATES WASTES & OPTIMIZES PROCESSES.
- COST REDUCTIONS THAT POSITIVELY IMPACTS THE ORGANIZATIONS BOTTOM LINE.

[Link] PROCESS EFFICIENCY:

- IDENTIFIES UNDERLAYING ISSUES IN PROCESS.
- ALLOWS IMPLEMENTATION OF STRATEGIES ENHANCING EFFICIENCY & EFFECTIVENESS.

[Link] A CULTURE OF CONTINUOUS IMPROVEMENT:

- EMBEDS A CULTURE WHERE INNOVATION AND EXCELLENCE ARE A WAY OF LIFE.

[Link] EMPLOYEE MORALE:

- BOOST MORALE & MOTIVATION THROUGH VISIBLE POSITIVE OUTCOMES.
- FOSTERS A WORKSPACE THAT THRIVES ON COLLABORATION & ACHIEVEMENT.
SIX SIGMA AS A BUSINESS STRATEGY

1. STEERS ORGANIZATIONS TOWARDS SUSTAINABLE GROWTH &

SUCCESS.
2. SERVES AS A VISION & PHILOSOPY THAT FOSTERS A CULTURE OF
EXCELLENCE & CONTINUAL GROWTH.
3. ALIGNS ALL ORGANIZATIONAL PROCESSES AND FUNCTIONS
FOR HIGHER EFFICIENCY & EFFECTIVENESS.
4. INSTILLS A MINDSET THRIVING ON DATA-DRIVEN DECISION-
MAKING.
5. MITIGATE RISKS & FOSTERS INNOVATION WITHIN THE
ORGANIZATION.
6. AIDS IN BRIDGING GAP BETWEEN VARIOUS DEPARTMENTS,
ENCOURAGING COHESIVE & ENERGIZED OPERATIONS.
7. TRANSFORM ORGANIZATIONS INTO AGILE, RESILIENT AND
CUSTOMER FOCUSED ENTITIES.
[Link] [Link]
(AGM-QAQC-VJ)
7083007799
sagarraskar7799@[Link]