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Which six sigma concept do you implement?

I work at a mid-sized manufacturing firm and we are trying to figure out how to best implement six sigma, if at all. Makers, Motorola, say six sigma can be used as three things: a metric, a methodology, and/or a management system. Which, if any, do you use and why?

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David O'Neill
Principal, Emertia, LLC
Posted on Aug. 30, 2010
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Your professional focus and previous questions indicate to me your business is in trying to work out where and how to get "lean". Not that all operations shouldn't pursue this end but mid-sized manufacturers are in that odd position of having certain economic constraints and enough differentiated management to question "how do we change" at a department/function level.

The scope and requirements of Six Sigma as a "management system" are beyond most organizations. The likes of GE and Motorola have enough excess managerial capacity and money to institutionalize change at that level. In GE's case this was done when Jack Welch lead with extreme powers - a useful state. In my oppinion, considering the level of understanding and time/money available, smaller organizations might better encourage learning Bodies of Knowledge such as CPIM or CSCP promoted by APICS.

The Six Sigma "measure" bit may be something of a misnomer. Most programs drive for savings based in improved quality (product and process.) Sometimes those quality changes are evaluated as continuing improvements i.e. stable reductions in waste. You don't necessarily need the level of statistics implied in the discipline. Measurement is important for lots of reasons but it shouldn't be an end in itself.

I believe good payback for SMBs comes from "lean" efforts, which includes the use of a wide range of tools including the DMAIC project management method. The statistical quality control tools can be very valuable in manufacturing and other operations. No less important is the clarity and throughput to be gained in back-office operations by analyzing value streams and eliminating non-value added procedures.

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Ondiappan Arivazhagan
CEO, International Institute of Project Management (IIPM)
Posted on Sept. 1, 2010
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Hi Mike,
At conceptual level, all three forms of six sigma are applicable and can be implemented in stages.

The following order of implementation may be tried.

1.Six Sigma as a "Metric". (COPQ, RTY, DPMO, Mistakes, etc)
2.Six Sigma as a "Methodology" ( DMAIC)
3.Six Sigma as a "Management system" (DFSS)

I suggest the following lean / six sigma techniques to start with. (not in any order)
1.Mistake Proofing (Poka-Yoke)
2.Failure Modes and Effects Analysis (FMEA)
3.5S
4.Standard Operating Procedures (SOP).

These are simple techniques ( at "Metrics" level, based on simple metrics like mistakes-before and mistakes-after by implementing mistake-proof technique to a CTQ of an existing process) to practice within your unit / dept. and you can easily see the initial success visibly which in turn will get you the necessary impetus and management buy-in for going to the next bigger level "Six Sigma as a methodology".

Ari

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David O'Neill
Principal, Emertia, LLC
Posted on Sept. 2, 2010
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I aggree with Ondiappan, DFSS can be part of a management system if it is instituionalized i.e. becomes the new product development platform. There is a higher level method as well. GE et al implement belt attainment as an expected course for employees binding the Six Sigma to organizational governance. So, maybe 4 levels?

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Eric Britten
President, Britten & Associates, LLC
Posted on Sept. 5, 2010
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Hi, Mike:

Check out a Focus Brief, The Pros and Cons of Six Sigma. You may find it helpful. (http://www.focus.com/briefs/operations/pros-and-cons-six-sigma/)

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