Utilizing Six Sigma in Lean Manufacturing Concepts

The key to Six Sigma is principles which aim at continuous improvement. When used in a manufacturing environment it can help a company to reduce errors and almost eliminate defective products from their production lines.

With Six Sigma in place processes are constantly monitored and improved to create the optimal work flow and processes.

The spirit of the Six Sigma process is also being adopted by the service industry, where they are thoroughly embracing its principles. Almost any industry these days is looking for a way to deliver constant improvements. Its immediate and long impact on the bottom line is a main factor in why Six Sigma has been embraced as a business practice and quality management practice.

The results of Six Sigma are much more than some abstract measurements that can only be measured after a significant period of time. There are concrete goals that can be measured almost immediately, such as the number of defective products, lowered inventory levels, and a reduction in the amount of customer returns. A look at these figures for before and after the implementation of Six Sigma will give a business a real sense of the benefits of the process. Below we will give answers to some of the most frequently asked questions about Six Sigma for those that are new to the concept.

How does an organization implement Six Sigma?
Implementing Six Sigma takes strong organization leadership, as well as excellent operational efficiency and discipline. The principles of Six Sigma will be used to closely analyze and alter each manufacturing process to achieve a reduction in the number of defects and defective products. Since it is unrealistic to think that every person and process in the company will be highly committed to this level of quality, Six Sigma utilizes in house quality champions to help achieve this goal. Six Sigma also relies heavily on the implementation of technology to help reduce errors.

This method of business process improvement requires that several professionals be employed for its implementation. Many consultants have in depth training and knowledge of the principles of Six Sigma, as well as manufacturing processes. Many are expects in a particular industry, such as automobiles or high tech manufacturing.

In order for your company to receive Six Sigma certification it will need to fully execute on project using the process that has been recommended by the consultants. A big part of the implementation of the Six Sigma process is the documenting the process and training company leaders. Implementing Six Sigma will also require a significant investment in man hours, machine hours, technology, and human resources.

The language of Six Sigma:
In today’s world where manufacturing processes are becoming increasingly complicated while at the same time quality is being stressed the Total Quality Management process of Six Sigma is becoming increasingly popular. Some of the major industries that are implementing Six Sigma include construction, banking, insurance, and healthcare. Six Sigma utilizes two main methodologies, are DMAIC (Define Measure Analyze, Improve and Control) and DMADV (Define, Measure, Analyze, Design and Verify). Six Sigma also has an operational hierarchy apart from that already established in the organization, including the senior management, Champions, Master Black Belts, Black Belts, and Green Belts. All of these positions have a specific task in the implementation of Six Sigma in the organization.

Why aren’t there more companies implementing Six Sigma if it has proven to be so effective?
Six Sigma was developed back in the 1980s and has stayed pretty much the same since then. One measure of its success is a manufacturing company achieving the amazing feat of only 3.4 defects per million products. Although its success is documented, it has mainly been large companies which have made the investment and commitment to Six Sigma. The cost for implementing the process is often too much for smaller companies to absorb. Another reason for the lack of implementation in smaller companies is the human resources required to manage the process.

Lean Six Sigma has been adopted by some companies which are sure that this quality management procedure is beneficial. Smaller organizations are better able to handle the reduced number for processes and steps that are included in Lean Six Sigma.

While this process began at Motorola, it can be a perfect match for any company which is committed to high quality and delivering improved service and products to its customers.