Six sigma is an organizational initiative designed to create manufacturing, service and administrative processes that produce a high rate of sustained improvement in both defect and cycle time reduction. Six Sigma is heavily inspired by preceding quality improvement methodologies like QMS, TQM, Zero defects etc.
Six Sigma is a statistical quality control mechanism that aims to achieve a maximum of 3.4 defects per million opportunities in any manufacturing process. Six Sigma was pioneered at Motorola with the initial objective of measuring the defects occurring in the manufacturing process and bringing them down to the minimum. Today, Six Sigma is being implemented in almost every organization,
in its financial, operational or production process. Since Six Sigma had led to high levels of customer satisfaction, it is being used across a range of industries, be it telecommunications, healthcare, insurance or software.
The term Six Sigma is derived from statistics. Sigma is a Greek symbol which is used to denote standard deviation or a variation from the Mean, or average in common language. The principle behind Six Sigma is to measure variations from the average and there by try to control them. In a production process, this concept would translate to a process of measuring defects and controlling them with an objective of ensuring a defect free production process.
Any Six Sigma project focuses on bringing about a breakthrough improvement systematically by managing defects and variations in any manufacturing process
or service transaction. This is achieved through two approaches,
• The DMAIC framework
• DFSS model
It may also happen that a project which may have started with the DMAIC framework is changed to a DFSS model if need for complete redesign is observed. Based on their level of expertise, experts in a Six Sigma project are called Belts. A yellow belt is at the lowest end of the skills spectrum, followed by the green belt,followed by the black belt and finally the Master Black Belt who is a mentor or trainer to the other belts.
This course aims at imparting and enhancing the participants understanding on Six Sigma approach for process improvements.
How participants will benefit after the course
Upon completion of this training, participants are expected to understand the intricacies of Six Sigma approach. Participants are expected to understand the
PDCA cycle and DMAIC approach. They are expected to identify projects for Six Sigma Initiative. Through rigorous class room exercises, students are expected to
gain working knowledge of various statistical tools and FMEA matrix. The training serves to all professionals desirous of identifying scientific methodology for quality improvement, defects reduction, inventory reduction and bottom line improvement.
Workshop topics to be covered:
Day I (Session I)
Introduction to Six Sigma
What is Six Sigma? Why Six Sigma?
History and Philosophy
How Six Sigma differs from other Quality Systems(ISO series of standards, APQP, Continuous improvement)
Plan Do Check Act(PDCA) Cycle
Day I (Session II)
Team Charter and Change Management
Statistical Background for six sigma processes
Principles and foundations of six Sigma (5S, Kaizen, DWM, Seven Wastes)
Day I (Session III)
Team Charter and Change Management (Continued)
Identifying internal and external resistance to change
Formulating Team and project charter
Identify and select project for six sigma initiative
Day I (Session IV)
Measurement System Analysis (MSA)
Day II (Session I)
MEASURE PHASE (Continued)
Top down charting
Cause and effect matrix
Testing of Hypothesis
Analysis of Variance, proportions (t- test, chi square test, ANOVA)
Day II (Session II)
Failure Mode Effect Analysis(FMEA)
Risk Priority number
Day II (Session III)
IMPROVE PHASE (Continued)
Problem solving( Brain Storming, six hat thinking, benchmarking)
How to implement new process?
Day II (Session IV)
Sustaining improvements though control plans and documents
Management system charts
Work Instructions and Standard Operating Procedures