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  • 1. What is Six Sigma Black Belt or Black Magic?
  • 2. Black Belt or Black Magic?
  • 3. What Do The Experts Say?
    • www.isixsigma.com
    • A goal of products and processes that experience only 3.4 defects per million or are 99.99966% good. - Nablusi
  • 4. What Do The Experts Say?
    • www.isixsigma.com
    • Six Sigma is a business system for achieving and sustaining success through customer focus, process management and improvement and the use of wise facts and data. - Anon.
      • Lean
      • TPM
      • TQM
      • Quality is Free
      • ____
      • Baldridge
      • Empowerment
      • Re-engineering
      • ISO
  • 5. What Do The Experts Say?
    • www.isixsigma.com
    • Let us be very clear that 6 sigma is not a new finding. It was there since the inception of the use of statistical control methods in the industry…. Six sigma is a measure of the non-conformance of a process … be it a manufacturing process or a non-manufacturing process like making sales invoices. Every company works … to reduce cost by adopting various methods. Most powerful amongst [these methods] is a statistical method … for reducing variability … till such time the process becomes … defect free. Such a … process is called 6 sigma. When you reach [6 sigma] … cost of quality is the lowest, reflected in the profits of the company. - Jawadekar
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  • 6. What Do The Experts Say?
    • www.isixsigma.com
    • I’m sorry, I don’t understand what your message is saying - Anon.
    • Six Sigma is a problem solving method for continuous improvement . This method focuses on the statistical analysis of data for making decisions for change. As a problem solving methodology it can be applied to almost any situation . - Duckworth
    • Six Sigma uses statistical analysis to graphically present data so even managers can make intelligent decisions - Mach
  • 7. What Do The Experts Say?
    • www.isixsigma.com
    • Six Sigma is nothing but simplification of product and processes which aims to take the defects to zero level. - Zeeshan
  • 8. What Do The Experts Say?
    • www.isixsigma.com
    • Six Sigma is a management methodology that combines a number of the tools and techniques we have always used in "quality initiatives". …this … data-driven approach requires that we … define defects, measure processes, analyze their capability and improve our processes from the shop floor to the back office. … we place appropriate control tools in place to … ensure that savings we have realized continue or increase. The success … lies in the ability to tie project results directly to bottom line savings and/or improved consumer satisfaction . - Johnson
  • 9. What Do The Experts Say?
    • www.isixsigma.com
    • Six Sigma is a customer centered, systematic, data driven method for doing things better
      • Customer centered means that projects start with, and are measured by, meeting customer wants and needs.
      • Systematic means that the Six Sigma tools are applied in concert, which makes them vastly more powerful than they are alone.
      • Data driven means that facts and data are used for making decisions.
    • Doing things better means, in some measurable, meaningful way, improving the situation of customers, workers, or shareholders of the organization . - Denton Bramwell, Sr. Master Black Belt, denton@bramwell.org
  • 10. Where Did Six Sigma Come From?
    • The Motorola Experience
    • Competition
      • Foreign – Japanese implementation of Deming
      • Domestic – Crosby “Quality is Free”
    • Zero Defects
      • 1970’s quality was: 3 sigma 99.933000% 67,000 DpM
    • 4 sigma 99.993800% 6,200 DpM
      • Cut the distribution in half !:
      • 6 sigma 99.999998% 2 DpM
      • A process shift of: 1.5 sigma 99.999997% 3.4 DpM
  • 11. Where Did Six Sigma Come From?
    • The Motorola Experience
    • Included quality tools and lessons from previous experience
    • A focus on:
      • Defect Prevention
      • Cycle Time Reduction
      • Cost Savings
    • Baldridge Quality Award 1988
      • Quality can be defined as “the value added by a productive endeavor”
      • Potential (maximum possible value) – Actual (current value)
      • = Waste
  • 12. Where Did Six Sigma Come From? The Motorola Experience “ One of Motorola’s most significant contributions was to change the discussion of quality from one where quality levels were measured in percentages (parts per hundred) to a discussion of parts per million or even parts per billion. Motorola correctly pointed out that … old ideas about acceptable quality levels were no longer acceptable.” Motorola’s Six Sigma Program – Thomas Pyzdek
  • 13. Where Did Six Sigma Come From?
  • 14. Where Did Six Sigma Come From?
    • “ Quality requires us to look … at our processes from the outside-in. By understanding the transaction lifecycle from the customer’s needs & processes, we can discover what they are seeing and feeling. With this knowledge… we can add significant value or improvement from their perspective.”
    • What is Six Sigma? The Roadmap to Customer Impact
    • www.ge.com/sixsigma
  • 15. The Critical Elements of Six Sigma?
    • Key Concepts
    • Critical to Quality - Most important attributes to the customer
    • Defect - Failure to deliver what the customer wants
    • Variation - What the customer sees and feels
    • Seek the elimination of defects
  • 16. The Critical Elements of Six Sigma?
    • “ Customers … define Quality. They expect performance, reliability, competitive prices, on-time delivery, service, clear & correct transaction processing & more. … being good is not enough. Delighting our customers is a necessity. Because if we don’t do it, someone else will !” - GE Six Sigma
  • 17. The Critical Elements of Six Sigma?
    • Key Concepts
    • Process Capability – What your process can deliver
    • Stable Operations – Ensuring consistent predictable processes to improve what the customer sees and feels
    • Variance – A change in a process or business practice that may alter its expected outcome
  • 18. The Critical Elements of Six Sigma?
    • “ The central idea behind Six Sigma is that if you can measure how many “defects” you have in a process, you can systematically figure out how to eliminate them and get as close to “zero defects” as possible.” - GE Six Sigma
  • 19. The Critical Elements of Six Sigma?
    • Key Concepts
    • Executive Engagement – Visible, consistent support and an active role in communication and reward
    • Stable Operations – Advocating and creating a “common language”. Including employees, customers and suppliers
    • Education and Training – Acquire, apply and foster the use of new or existing Knowledge to improve capabilities
    • Alignment – Engage the entire organization to improve every process and practice
  • 20. The Critical Elements of Six Sigma?
    • Key Concepts
    • Customer Focus – Integrate the customer into the organization. Listen to them!
    • Data Driven – Critical to Quality (CTQ), Defects, Pareto Charts, Root Cause Analysis, Process Mapping, Control Charts, Statistical Process Control, Gage R&R, Brainstorming, FMEA (Failure Mode Effect Analysis), Design of Experiments
    • Robust Methodology – (1) DMAIC (Define, Measure, Analyze, Improve, Control) - Continued improvement on existing processes. (2) DMADV (Define, Measure, Analyze, Design, Verify) – New product or processes.
    Defining Six Sigma for your Business or Organization – Zack Swinney
  • 21. Black Belt or Black Magic? “ Six Sigma’s magic isn’t in statistical or high-tech razzle-dazzle. Six Sigma relies on tried and true methods that have been around for decades. In fact, Six Sigma discards a great deal of the complexity that characterized Total Quality Management (TQM). By one expert’s count, there were over 400 TQM tools and techniques. Six Sigma takes a handful of proven methods … the tools are applied within a simple performance improvement model known as DMAIC.” Six Sigma Revolution Thomas Pyzdek
  • 22. Black Belt or Black Magic? P/T 1/10 Project Team Leader Green Belt F/T 1/100 “ Journeyman” expert Responsible for implementation of Six Sigma projects Black Belt F/T 1/1000 Train-the-trainer An expert who trains and mentors Six Sigma project leaders Master Black Belt
  • 23. Black Belt or Black Magic?
    • Success requires 3 things only
      • Recognize the problem
      • Take ownership
      • Work out the details
    • “ Experts who can “work out the details” are a dime-a-dozen. Hire a full-time person or rent a consultant.” - Doug Welter
  • 24. Is That All There Is? “ Some people, including me, believe that garden variety six sigma doesn't go far enough. In fact, even zero defects falls short. … Progressive people in the six sigma camp … looks for critical-to-quality (CTQ) characteristics in a product or service. CTQ features are those that customers expect and consider explicitly … A product or service that doesn't provide the CTQ features that customers expect suffers lower customer satisfaction. But even this definition isn't enough. ” Six Sigma and Beyond Thomas Pyzdek
  • 25. Is That All There Is? The Kano Model
  • 26. Where To From Here? “ Long-term success requires the customer to be excited by unexpected innovations provided by a company's products and services: Continued survival requires that your organization continuously innovate. Innovation is the result of creative activity, not of analysis. Creativity can't be achieved "by the numbers." In fact, excessive attention to a rigorous process such as six sigma actually detracts from creativity.” Six Sigma and Beyond Thomas Pyzdek
  • 27. Where To From Here? The Kano Model INNOVATION
  • 28. Six Sigma or Lean? Kaizan or Kanban?
    • Lean is about reducing or eliminating all activities that do not add value. It reduces or eliminates 8 principle sources of waste:
      • Waiting - set-up, changeover, no work, no operator, downtime
      • Inventory - stagnant Work-in-Process, spare parts, just-in-case
      • Overproduction - batch runs, minimum run rates
      • Extra Processing - rework, conditioning
      • Motion - non-adjacent processing, go-fer
      • Transportation - moving product
      • Defects - rejects
      • Underutilized People - THE GREATEST WASTE OF ALL!
  • 29. Six Sigma or Lean? Kaizan or Kanban? Tools in the Toolbox SIX SIGMA LEAN INNOVATION
  • 30. Six Sigma: Black Belt or Black Magic?
    • Six Sigma is:
    • Customer Centered • Systematic • Data Driven
    • Customer Centered
    • Critical to Quality: Attributes defined by customer
    • Defect: Failure to Deliver what the customer expects
    • Variation – Customer Impression
    • Continuous Improvement:
    • 3 sigma 6 sigma Zero Defects
  • 31. Six Sigma: Black Belt or Black Magic?
    • Six Sigma is:
    • Customer Centered • Systematic • Data Driven
    • Systematic
    • DMAIC or DMADV - Stable Operations (consistent, predictable), Control Variance, Process Capability (reach & improve)
    • Executive Engagement: Visible, consistent support and active
    • Communication: Common language – customers, employees & suppliers
    • Education and Training: Acquire, apply and foster knowledge
    • Alignment: Engage the entire organization to improve every process
  • 32. Six Sigma: Black Belt or Black Magic?
    • Six Sigma is:
    • Customer Centered • Systematic • Data Driven
    • Data Driven
    • Use the tools in the toolbox (old favorites or new tools)
    • Use the right tool in the right way
    • Lean – Six Sigma
  • 33. Six Sigma: Black Belt or Black Magic?
    • Six Sigma is:
    • Customer Centered • Systematic • Data Driven
    • AND
    • Doing things Better
      • Innovate!
      • Delight Your Customer!
      • If you don’t, someone else will!!!
  • 34. For additional information contact: Michelle Brown 208.364.4999 [email_address]