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`@ IJTSRD | Available Online @ www.ijtsrd.com
ISSN No: 2456
International
Research
Roadmap of Six Sigma for Engineering Colleges
Mr. K. R. Gawande
Research Scholar, Shri J. J. T. University,
Jhunjhunu, Rajasthan, India
ABSTRACT
A quality improvement tool called Six Sigma and its
extension Lean Sigma has gained lot of attention and
importance in service sector especially in engineering
education. Six Sigma has several benefits in education
and specifically provides a competitive edge over
others. As per the old belief that only manufacturing
organizations can be benefitted by Six Sigma, now a
day study found the tremendous applications and
applicability of Lean and Six Sigma in engineering
colleges. There are still a number of issues related to
the nature of education systems that must be resolved
before the full benefits of Six Sigma can be realized.
In this paper, the issue related with the practical
application and implementation of Six Sigma through
various angles as such: analytical, institutional, and
personal point are studied. Awareness of the existence
of such issues, if not the answers to all of them, is a
pre-requisite to effective adoption of Six Sigma tools.
A general roadmap for Six Sigma that can be
applicable in engineering colleges is presented here.
Keywords: Zero defects, Lean and Six Sigma; DPMO;
Service sector; Engineering education, Quality
Management
I. INTRODUCTION
Since 1980 Six Sigma has found applications in
manufacturing organisations and because of its
tremendous benefits and effectiveness it has been
accepted by many organisations. The tools of Six
Sigma along with its statistical thinking have attracted
many organisations as well. Design for Six Sigma or
DFSS and Lean Six Sigma have gained much
attention because of their effective outputs for built in
@ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 1 | Issue – 6 | Sep - Oct 2017
ISSN No: 2456 - 6470 | www.ijtsrd.com | Volume
International Journal of Trend in Scientific
Research and Development (IJTSRD)
International Open Access Journal
Roadmap of Six Sigma for Engineering Colleges
University,
Jhunjhunu, Rajasthan, India
Prof. Dr. Rajeev V. V.
Principal, Sabar Institute of Technology
for Girls, Sabarkantha,
A quality improvement tool called Six Sigma and its
extension Lean Sigma has gained lot of attention and
importance in service sector especially in engineering
its in education
and specifically provides a competitive edge over
others. As per the old belief that only manufacturing
organizations can be benefitted by Six Sigma, now a
day study found the tremendous applications and
in engineering
colleges. There are still a number of issues related to
the nature of education systems that must be resolved
before the full benefits of Six Sigma can be realized.
In this paper, the issue related with the practical
ntation of Six Sigma through
various angles as such: analytical, institutional, and
personal point are studied. Awareness of the existence
of such issues, if not the answers to all of them, is a
requisite to effective adoption of Six Sigma tools.
eral roadmap for Six Sigma that can be
applicable in engineering colleges is presented here.
Lean and Six Sigma; DPMO;
Service sector; Engineering education, Quality
Since 1980 Six Sigma has found applications in
manufacturing organisations and because of its
tremendous benefits and effectiveness it has been
accepted by many organisations. The tools of Six
Sigma along with its statistical thinking have attracted
Design for Six Sigma or
DFSS and Lean Six Sigma have gained much
attention because of their effective outputs for built in
performance at the stage of design and considerable
efficiency at the stage of production.
As Six Sigma promises to reduce the rejection rate,
which is termed as DPMO or defects per million
opportunities, its principles are spread beyond
manufacturing to service and up to education. There is
a quite large use of Six Sigma and/or Lean Sigma in
service sectors, which was earlier, thought the area of
only manufacturing sector. We find now a days there
is a boon of service sectors from off line firms to on
line firms, providing various types of services and
hence Six Sigma with its tools find a perfect place to
capture the attention of these firms. This is the real
time for Six Sigma to rise today and find its place in
these service organizations particularly in engineering
education. It is realized however as there are basic
differences in manufacturing and service
pragmatic issues came in to existence during its actual
application, some of which may not even have been
brought up to the attention of Six Sigma learners. It is
certainly useful to discuss such issues and their impact
on the effectiveness of Six Sigma; even when
complete solutions are not available, the mere
awareness would play an important role in defining
one’s understanding of the potential
limitations as well – of the tools of Six Sigma, and
helping to shape realistic expe
application projects anywhere.
In this paper the author focuses three general aspects,
though these are not limited to, as (1) the analytical
level; (2) the institutional level, and (3) the personal
level. Such classification of ite
formulating counter-plans or solutions, although there
Oct 2017 Page: 977
6470 | www.ijtsrd.com | Volume - 1 | Issue – 6
Scientific
(IJTSRD)
International Open Access Journal
Roadmap of Six Sigma for Engineering Colleges
Prof. Dr. Rajeev V. V.
Principal, Sabar Institute of Technology
for Girls, Sabarkantha, Gujarat, India
performance at the stage of design and considerable
efficiency at the stage of production.
omises to reduce the rejection rate,
which is termed as DPMO or defects per million
opportunities, its principles are spread beyond
manufacturing to service and up to education. There is
a quite large use of Six Sigma and/or Lean Sigma in
which was earlier, thought the area of
only manufacturing sector. We find now a days there
is a boon of service sectors from off line firms to on
line firms, providing various types of services and
hence Six Sigma with its tools find a perfect place to
ture the attention of these firms. This is the real
time for Six Sigma to rise today and find its place in
these service organizations particularly in engineering
education. It is realized however as there are basic
differences in manufacturing and service, a number of
pragmatic issues came in to existence during its actual
application, some of which may not even have been
brought up to the attention of Six Sigma learners. It is
certainly useful to discuss such issues and their impact
f Six Sigma; even when
complete solutions are not available, the mere
awareness would play an important role in defining
one’s understanding of the potential – and perhaps
of the tools of Six Sigma, and
helping to shape realistic expectations on outcomes of
application projects anywhere.
In this paper the author focuses three general aspects,
though these are not limited to, as (1) the analytical
level; (2) the institutional level, and (3) the personal
level. Such classification of items will help
plans or solutions, although there
International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
`@ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 1 | Issue – 6 | Sep - Oct 2017 Page: 978
could be other ways, for example presenting an all-
inclusive analysis in accordance to the DMAIC (Do-
Measure-Analyse-Improve-Control) methodology and
a general roadmap of Six Sigma for engineering
colleges.
II. SERVICE SECTOR AND ENGINEERING
EDUCATION
Service sector provides services only they do not
create tangible products and this is the main common
characteristic of all service sectors. Besides this they
can take various shapes and forms like picking your
clothes from your door step for laundry to taking
lunch in a restaurant, or peace campaign in a war
prone area, the list and experience of service is quite
vast. Sometimes attempts are made to formally and
positively define a service system though most Six
Sigma practitioners tend to use a reverse approach,
namely regarding anything non-manufacturing as
service. Description or definition of service by
exception may have difficulties, for example it would
put certain types of human effort such as agriculture
and warfare into ill-defined categories. However, if
one is to limit one’s attention to systems commonly
encountered in modern and developed communities –
such as transportation, healthcare, finance, education
– then the concept of service quality is easier to grasp.
Hence for the sake of explaining the topic, here the
definition of service is considered as said above and
not as rigorous as been put forward by some experts.
As global competition in education becoming more
intense, institutions are trying to implement strategies
that allow them become more efficient, increase
quality and productivity, and stay ahead of their
competition. Over the years, there have been different
programs or methodologies that institutions have
adopted with the purpose of achieving enhanced
operational performance and overall quality of the, let
us say, engineering education. Six Sigma is one of the
strategies that have gained more popularity during
recent years, being adopted by some selected
institutions in engineering education as well.
In spite of the challenges and difficulties of
implementing Six Sigma in an academic environment,
the literature shows that there are Six Sigma project
successes in selected universities and institutions.
Various authors have written articles about Six Sigma
in education, role of academia in Six Sigma
education, including case studies also.
III. PROCESS OF BENCHMARKING AND
THE ROADMAP
The Six Sigma improvement model typically has five
phases: Define, Measure, Analyse, Improve and
Control: the same is casted to suit the engineering
education setting. As shown in the figure 1 the
college management is solely responsible for creating
change environment in the college, which is the
utmost requirement of any Six Sigma project.
Management is the main driving force behind all
activities that determines the success and failure of the
Six Sigma project in the college.
Phase 1- Define: In the Define phase, the college has
to form a Six Sigma team, including members from
different departments and students as well, affected by
the problem. The engineering college has to define the
project charter mentioning clearly, responsibility and
accountability. The team clearly specifies the problem
and tries to quantify its qualitative impact on the
overall engineering education and engineering
college. The SIPOC diagram is resulted in the define
phase. The team identifies metrics to assess the
impact of the problem in the past, and to document
improvements as the problem is fixed.
Phase 2- Measure: In the Measure phase, the Six
Sigma team studies the academic and other process in
engineering college and measurements associated
with the problem. The team produces process maps
and assesses the accuracy and precision of
measurement systems. If necessary, the team
establishes new metrics. The team identifies potential
causes for the problem by applying a variety of
statistical tools. The data for the potential causes of
variation is collected and some major causes are
differentiated termed as CTQ’s.
Phase 3- Analyze: In the Analyze phase, the Six
Sigma team determines what actually causes the
problem. To do this, they apply a variety of statistical
tools to test hypotheses and experiment on the
process. Many times surveys, discussions and
interviews are carried out to get insight in to the
causes of the problems and their remedies. Once the
relationship between the causes, effects and their
remedies is understood, the team can determine how
best to improve the process, and how much benefit to
expect from the improvement.
Phase 4- Improve: In the Improve phase, the Six
Sigma team implements changes to improve process
performance. The remedies that came out in the
analyse phase are implemented in improve phase, the
International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
`@ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 1 | Issue – 6 | Sep - Oct 2017 Page: 979
improvement is again checked with some statistical
tools and via some charts and graphs. The data is
compared with the already stated objectives. Using
the metrics already deployed, the team monitors the
process to verify the expected improvement.
Phase 5- Control: In the Control phase, the Six
Sigma team selects and implements methods to
control future process variation. These methods could
include documented procedures or statistical process
control methods. This vital step assures that the same
problem will not return in the future. With the process
completed, the Six Sigma team disbands or if required
it again takes the same or other problem to reduce
process variation with higher/stringent objectives.
Monitoring and comparing is the motto of this phase
otherwise there lies the threat that the process may
slip to its original state.
Fig. 1 Six Sigma Roadmap (general) in an Institute
IV. PRODUCT (STUDENTS) QUALITY
ISSUES
In the study of quality management, customer
satisfaction and business competitiveness of
educational institutes there are a number of attributes
of educational institutes that differentiate educational
institutes from service and manufacturing. These may
be categorized as follows:
1. Identification of “defects” and, those are critical
to quality:
a. What constitutes a defect or defective could be
very personal and hence subjective.
b. Delays are common in the recognition of defects
or defectives.
c. A defect or defective is often more readily noticed
(and seems more critical) than a “good” outcome.
d. Level of quality tends to be measured and
compared via a negative scale (e.g. DPMO
(defects per million opportunities), instead of
yield; complaints about educational system and
facilities tend to be more attention-catching than
compliments).
2. Nature or basis for improvement:
a. In a given study, the process in question can be,
and often is, more relevant or felt more important
than the product.
b. An instance of service tends to have to be highly
customized for all the students (like
standardization or mass production in
manufacturing).
c. The role of raw material, that is input students and
faculties, is usually high.
d. Inventorization, i.e. accumulation of services, is
normally not done.
3. Feasibility of applying analytical tools:
a. Standardization, calibration and benchmarking
could be inadequate, difficult, or sometimes
impossible.
b. Product quality relates much more with
information flow and utilization than what many
traditional quality practitioners are used to.
c. Available information tends to be quantitative (i.e.
continuous or measured data) rather than
qualitative (i.e. discrete or attribute data).
d. Educational systems do not lend themselves
readily to data-intensive methodologies such as
those entailed in Six Sigma.
4. Situation or institute specific issues:
a. Specification limits or tolerances not only tend to
be arbitrary or impossible, it could also be
location/society-dependent and time-varying.
b. System boundary could be difficult to draw in a
study; noise is usually large and, by definition,
and nearly not controllable.
c. Customers themselves could be voluntarily or
involuntarily involved in the way service is
generated.
d. Cultural factors, values and ethics could be
involved in judgments. Thus a person familiar
with manufacturing process studies has to adopt a
very different approach when it comes to
educational systems. Most educational systems are
in need of improvement in the sense of a Kano
quality system -- Kano (1984) -- rather than
International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
`@ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 1 | Issue – 6 | Sep - Oct 2017 Page: 980
reduction of DPMO: in fact coupled with human
emotions, sentiments and expectations, it is near
impossible to define flawlessly a “defect”.
V. ANALYTICAL ISSUES
When educational institutes’ wants to apply Six
Sigma in their organizations, the greatest difficulty or
barrier comes from the individuals having higher
qualification and experiences with strong desire to sit
on higher positions with no knowledge of the
processes and their impacts. They fail to answer what
is required to be done? How it is to be done? And
what will be the output exactly? They try every body
part other than the ‘soul’. Energy is wasted in undoing
what they have previously done in conventional
manner.
The original Six Sigma methodology was motivated
by arguments based on a normal distribution. All the
concepts of 3.4 dpmo as a bench mark, z scores,
short-term and long-term performances and so on, are
derived and extended based on normal distributions.
While the behaviour of many natural physical
quantities can be approximated by the normal
distribution, the same cannot be said of common
educational systems; for example the Poisson
distribution is more likely to be appropriate to
describe lapses in a specific type of service. With the
collapse of the normal distribution background, the
idea of “sigma level” as a proxy for “quality level”,
with the attendant arguments about improvements,
comparisons and so on, is no longer valid. Thus a Six
Sigma project cannot be based on concepts of “sigma
level” without checking the behaviour of background
data. Even if the normal distribution is a reasonable
approximation, there are still arguments against the
non-linear nature of “improvement”; for example the
dpmo reduction for a change from five sigma level to
six sigma level is very different from a change from
two sigma level to three sigma level. Other
controversies, such as the rationale for 1.5 sigma shift
in the long term, also carry over from the study of
manufacturing systems to that of educational and
other service systems; the justifications are, if
anything, even more uncertain or unconvincing in the
latter. What is even more challenging, from a
statistical modelling point of view, is that many
educational systems tend to be time-variant owing to
changing expectations, lifestyle, culture, demography,
political decisions, and so on. Assumptions about
noise behaviour, often taken for granted in the
modelling of manufacturing processes, cannot be
made lightly: For example, data independence is an
important yet often ignored requirement in system
modelling – as a result of the shallow Statistics
training or knowledge of some practitioners. Merely
collecting data is not quality.
VI. INSTITUTIONAL ISSUES
A common desire of management is to attain the
highest quality and achievements. They want to know
about Six Sigma as they have heard it from so many
sources and from media publications also. Some were
promised by so called educational consultants that
each project would attract flock of students and lacks
of rupees. The usefulness or otherwise of such
“motivation” is obvious if it is realized that not every
organization operates in the same scale, same
structure, same product (students) or same input
(fresher). The ‘environment’ is ‘different’.
All these exciting claims are often repeated in
brochures and manuals selling Six Sigma courses
which by the way are often expensive, and as a rule
training or consulting fees are expected way before
any real savings are realized by the clients. All these
point to the need for a proper understanding of the
principles and rationale behind Six Sigma before its
adoption. Six Sigma is not a fad, and educational
institutes should not go for it simply because the
competition has it, some learned people talk about it,
and they themselves feel that this is perhaps good
public reputation. Institute needs to create a Six
Sigma team as roadmap shown in figure 2, with rights
and responsibilities given to it. The Six Sigma team
will then be responsible for the way the project
carried out in the institution. Institute has to select,
train and motivate people in the institute for the
success of the Six Sigma project. Institutes following
norms of Governing body completely may find it
achievable if approached properly for it.
Another possibility is to keep unrealistic expectations
after hearing the propaganda from incompetent or
irresponsible consultants, trainers and faculty
members: disillusionment about Six Sigma after
payment of hefty amount and deploying expensive
manpower in vain would double the pain. To claim
that Six Sigma can only lead to business success for
any organization is just being irresponsible.
International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
`@ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 1 | Issue – 6 | Sep - Oct 2017 Page: 981
Fig. 2 Six Sigma Roadmap (local) in an Institute
VII. PERSONAL ISSUES
Educational organizations requires individuals those
can give output. Merely having eligibility does not
mean the individual is suitable for the Six Sigma
project. Then who can decide the right person?
Overly optimistic thinking about individuals could
lead to disillusion in ways as explained above, but the
tendency today seems to suggest that it is not
organizations, but rather individuals, that are keen
about Six Sigma. Witness the advertisements for
training courses for “Belts” of all sorts of colours – of
course Black Belts in particular. Almost all such
advertisements promise certification: certification of
the individual as, for example, Black Belt, rather than
an organization. This is in fact a deviation from the
original motivation: to improve organizational
performance and increase customer satisfaction. It is a
fact that nowadays many people sign up for Six
Sigma training not necessarily motivated by the
operation of the company, but by the certificate that
they themselves could possess at the end to improve
their CV. Most training and certification programs
also require demonstration of competence via a
presentation on projects, which not infrequently then
lead to some sort of “reverse engineering” – armed
with final solutions and results, the “problem solving”
or “improvement” process is developed backwards so
that the resulting material would fit the expectation of
the certification examiners, in a format that inevitably
ends with “all is well”. This is not to suggest a
termination of the existing Six Sigma training and
certification system. What is needed is an ability to
avoid not seeing the forest for the trees, and a serious
attitude toward Six Sigma projects. There is no rule
that says all such projects must end in “all is well”. It
is “statistical thinking” that is called for in the
execution of projects, and the thoroughness of its
application determines the merit of the work. If this
point is not appreciated, more individuals will
engineer projects “suitable” for certification purposes,
but the resulting Black Belts or Green Belts cannot be
expected to be able to handle uncertainties of
educational systems intelligently and bring credit to
Six Sigma.
VIII. CONCLUDING REMARKS
Engineering educational sector is nowadays a
lucrative business as it is playing important role in the
economy of a country. At the same time this sector is
constantly searching for better tools for
improvements. Six Sigma is one such tool which
offers various gains not certainly possible by others.
In this hope these organisations trying for Six Sigma
and at the same time it is presenting considerable
challenges to those who apply it. In this paper, a
counter point is shown between education, service and
manufacturing, followed by discussions concerning
the application of Six Sigma at the analytical,
institutional and personal levels. There are varying
degrees of “goodness of fit” of the descriptions when
it comes to individual cases, but universal
applicability is by no means implied. As the Six
Sigma methodology evolves and as more training and
certification programs emerge in the commercial
world, it is important that a rational perspective be
maintained before investments are made in Six Sigma
by an organization for its deployment, or by a person
for whatever manner of “certification”, as unrealistic
expectations could only lead to disillusionment. It is
worthwhile noting that Six Sigma has been largely
propagated outside academia and embraced by
industry, which gives it a practical bent but would
also mean that occasionally insufficient attention is
paid to the related theoretical underpinning. The
enthusiasm that is seen nowadays for personal
certification is necessary but by no means sufficient to
spread the effective practice of Six Sigma especially
in educational systems. Indeed it must be said that it is
only an organization with a critical mass of
individuals with statistical thinking, not some certified
individuals more concerned with their qualifications
than customer benefits, could bring the true power to
the educational institute.
REFERENCES
1) Arun Vijay S. (2013). “Appraisal of Student
Rating as a Measure to Manage the Quality of
Higher Education in India: An Institutional Study
Using Six Sigma Model Approach,” International
International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
`@ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 1 | Issue – 6 | Sep - Oct 2017 Page: 982
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“The Role of Six Sigma in Improving the Quality
of Higher Education Institutions,” The SIJ
Transactions on Industrial, Financial & Business
Management (IFBM), Vol. 3, No. 6, ISSN: 2321-
242X, June 2015, pp. 93-98.
10) Naveen Kumar and Dr. R.M.Belokar (2015). “Six
Sigma in Education System: A Review,”
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Development, Vol. 3, Issue 03, 2015, ISSN
(online): 2321-0613, pp. 3504-3507.
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Desintonio (2016). “A proposed framework for
implementing Lean Six Sigma methodology in
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SigmaUsing SigmaXL and Minitab,” Mc Graw
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16) Tannu Vats and Sujata (2015). “Lean six sigma
model to improve student performance,”
International Journal of Computer Science and
Technology, IJCST Vol. 6, Issue 2, April - June
2015, ISSN : 0976-8491 (Online).
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Six-Sigma in the Service Industry: A Review and
Case Study in Call center services,” 2006 IEEE
International Conference on Management of
Innovation and Technology
18) Deshmukh, S.G., N. Seth and P. Vrat (2005).
“Service Quality Models: A Review,”
International Journal of Quality & Reliability
Management, Vol.22, No.9, pp. 913–949, 2005.
19) David Fogarty (2015). “Lean six sigma and data
analytics: Integrating complementary activities,”
International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
`@ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 1 | Issue – 6 | Sep - Oct 2017 Page: 983
Global Journal of Advanced Research, 2015, Vol-
2, Issue-2, ISSN: 2394-5788, pp. 472 -480.
20) Prof. Thong-Ngee Goh (2012). “Some practical
issues in the application of lean six sigma to
service systems.” Nang Yan Business Journal –
1.1, 2012, pp. 21-26.

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Roadmap of Six Sigma for Engineering Colleges

  • 1. `@ IJTSRD | Available Online @ www.ijtsrd.com ISSN No: 2456 International Research Roadmap of Six Sigma for Engineering Colleges Mr. K. R. Gawande Research Scholar, Shri J. J. T. University, Jhunjhunu, Rajasthan, India ABSTRACT A quality improvement tool called Six Sigma and its extension Lean Sigma has gained lot of attention and importance in service sector especially in engineering education. Six Sigma has several benefits in education and specifically provides a competitive edge over others. As per the old belief that only manufacturing organizations can be benefitted by Six Sigma, now a day study found the tremendous applications and applicability of Lean and Six Sigma in engineering colleges. There are still a number of issues related to the nature of education systems that must be resolved before the full benefits of Six Sigma can be realized. In this paper, the issue related with the practical application and implementation of Six Sigma through various angles as such: analytical, institutional, and personal point are studied. Awareness of the existence of such issues, if not the answers to all of them, is a pre-requisite to effective adoption of Six Sigma tools. A general roadmap for Six Sigma that can be applicable in engineering colleges is presented here. Keywords: Zero defects, Lean and Six Sigma; DPMO; Service sector; Engineering education, Quality Management I. INTRODUCTION Since 1980 Six Sigma has found applications in manufacturing organisations and because of its tremendous benefits and effectiveness it has been accepted by many organisations. The tools of Six Sigma along with its statistical thinking have attracted many organisations as well. Design for Six Sigma or DFSS and Lean Six Sigma have gained much attention because of their effective outputs for built in @ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 1 | Issue – 6 | Sep - Oct 2017 ISSN No: 2456 - 6470 | www.ijtsrd.com | Volume International Journal of Trend in Scientific Research and Development (IJTSRD) International Open Access Journal Roadmap of Six Sigma for Engineering Colleges University, Jhunjhunu, Rajasthan, India Prof. Dr. Rajeev V. V. Principal, Sabar Institute of Technology for Girls, Sabarkantha, A quality improvement tool called Six Sigma and its extension Lean Sigma has gained lot of attention and importance in service sector especially in engineering its in education and specifically provides a competitive edge over others. As per the old belief that only manufacturing organizations can be benefitted by Six Sigma, now a day study found the tremendous applications and in engineering colleges. There are still a number of issues related to the nature of education systems that must be resolved before the full benefits of Six Sigma can be realized. In this paper, the issue related with the practical ntation of Six Sigma through various angles as such: analytical, institutional, and personal point are studied. Awareness of the existence of such issues, if not the answers to all of them, is a requisite to effective adoption of Six Sigma tools. eral roadmap for Six Sigma that can be applicable in engineering colleges is presented here. Lean and Six Sigma; DPMO; Service sector; Engineering education, Quality Since 1980 Six Sigma has found applications in manufacturing organisations and because of its tremendous benefits and effectiveness it has been accepted by many organisations. The tools of Six Sigma along with its statistical thinking have attracted Design for Six Sigma or DFSS and Lean Six Sigma have gained much attention because of their effective outputs for built in performance at the stage of design and considerable efficiency at the stage of production. As Six Sigma promises to reduce the rejection rate, which is termed as DPMO or defects per million opportunities, its principles are spread beyond manufacturing to service and up to education. There is a quite large use of Six Sigma and/or Lean Sigma in service sectors, which was earlier, thought the area of only manufacturing sector. We find now a days there is a boon of service sectors from off line firms to on line firms, providing various types of services and hence Six Sigma with its tools find a perfect place to capture the attention of these firms. This is the real time for Six Sigma to rise today and find its place in these service organizations particularly in engineering education. It is realized however as there are basic differences in manufacturing and service pragmatic issues came in to existence during its actual application, some of which may not even have been brought up to the attention of Six Sigma learners. It is certainly useful to discuss such issues and their impact on the effectiveness of Six Sigma; even when complete solutions are not available, the mere awareness would play an important role in defining one’s understanding of the potential limitations as well – of the tools of Six Sigma, and helping to shape realistic expe application projects anywhere. In this paper the author focuses three general aspects, though these are not limited to, as (1) the analytical level; (2) the institutional level, and (3) the personal level. Such classification of ite formulating counter-plans or solutions, although there Oct 2017 Page: 977 6470 | www.ijtsrd.com | Volume - 1 | Issue – 6 Scientific (IJTSRD) International Open Access Journal Roadmap of Six Sigma for Engineering Colleges Prof. Dr. Rajeev V. V. Principal, Sabar Institute of Technology for Girls, Sabarkantha, Gujarat, India performance at the stage of design and considerable efficiency at the stage of production. omises to reduce the rejection rate, which is termed as DPMO or defects per million opportunities, its principles are spread beyond manufacturing to service and up to education. There is a quite large use of Six Sigma and/or Lean Sigma in which was earlier, thought the area of only manufacturing sector. We find now a days there is a boon of service sectors from off line firms to on line firms, providing various types of services and hence Six Sigma with its tools find a perfect place to ture the attention of these firms. This is the real time for Six Sigma to rise today and find its place in these service organizations particularly in engineering education. It is realized however as there are basic differences in manufacturing and service, a number of pragmatic issues came in to existence during its actual application, some of which may not even have been brought up to the attention of Six Sigma learners. It is certainly useful to discuss such issues and their impact f Six Sigma; even when complete solutions are not available, the mere awareness would play an important role in defining one’s understanding of the potential – and perhaps of the tools of Six Sigma, and helping to shape realistic expectations on outcomes of application projects anywhere. In this paper the author focuses three general aspects, though these are not limited to, as (1) the analytical level; (2) the institutional level, and (3) the personal level. Such classification of items will help plans or solutions, although there
  • 2. International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470 `@ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 1 | Issue – 6 | Sep - Oct 2017 Page: 978 could be other ways, for example presenting an all- inclusive analysis in accordance to the DMAIC (Do- Measure-Analyse-Improve-Control) methodology and a general roadmap of Six Sigma for engineering colleges. II. SERVICE SECTOR AND ENGINEERING EDUCATION Service sector provides services only they do not create tangible products and this is the main common characteristic of all service sectors. Besides this they can take various shapes and forms like picking your clothes from your door step for laundry to taking lunch in a restaurant, or peace campaign in a war prone area, the list and experience of service is quite vast. Sometimes attempts are made to formally and positively define a service system though most Six Sigma practitioners tend to use a reverse approach, namely regarding anything non-manufacturing as service. Description or definition of service by exception may have difficulties, for example it would put certain types of human effort such as agriculture and warfare into ill-defined categories. However, if one is to limit one’s attention to systems commonly encountered in modern and developed communities – such as transportation, healthcare, finance, education – then the concept of service quality is easier to grasp. Hence for the sake of explaining the topic, here the definition of service is considered as said above and not as rigorous as been put forward by some experts. As global competition in education becoming more intense, institutions are trying to implement strategies that allow them become more efficient, increase quality and productivity, and stay ahead of their competition. Over the years, there have been different programs or methodologies that institutions have adopted with the purpose of achieving enhanced operational performance and overall quality of the, let us say, engineering education. Six Sigma is one of the strategies that have gained more popularity during recent years, being adopted by some selected institutions in engineering education as well. In spite of the challenges and difficulties of implementing Six Sigma in an academic environment, the literature shows that there are Six Sigma project successes in selected universities and institutions. Various authors have written articles about Six Sigma in education, role of academia in Six Sigma education, including case studies also. III. PROCESS OF BENCHMARKING AND THE ROADMAP The Six Sigma improvement model typically has five phases: Define, Measure, Analyse, Improve and Control: the same is casted to suit the engineering education setting. As shown in the figure 1 the college management is solely responsible for creating change environment in the college, which is the utmost requirement of any Six Sigma project. Management is the main driving force behind all activities that determines the success and failure of the Six Sigma project in the college. Phase 1- Define: In the Define phase, the college has to form a Six Sigma team, including members from different departments and students as well, affected by the problem. The engineering college has to define the project charter mentioning clearly, responsibility and accountability. The team clearly specifies the problem and tries to quantify its qualitative impact on the overall engineering education and engineering college. The SIPOC diagram is resulted in the define phase. The team identifies metrics to assess the impact of the problem in the past, and to document improvements as the problem is fixed. Phase 2- Measure: In the Measure phase, the Six Sigma team studies the academic and other process in engineering college and measurements associated with the problem. The team produces process maps and assesses the accuracy and precision of measurement systems. If necessary, the team establishes new metrics. The team identifies potential causes for the problem by applying a variety of statistical tools. The data for the potential causes of variation is collected and some major causes are differentiated termed as CTQ’s. Phase 3- Analyze: In the Analyze phase, the Six Sigma team determines what actually causes the problem. To do this, they apply a variety of statistical tools to test hypotheses and experiment on the process. Many times surveys, discussions and interviews are carried out to get insight in to the causes of the problems and their remedies. Once the relationship between the causes, effects and their remedies is understood, the team can determine how best to improve the process, and how much benefit to expect from the improvement. Phase 4- Improve: In the Improve phase, the Six Sigma team implements changes to improve process performance. The remedies that came out in the analyse phase are implemented in improve phase, the
  • 3. International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470 `@ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 1 | Issue – 6 | Sep - Oct 2017 Page: 979 improvement is again checked with some statistical tools and via some charts and graphs. The data is compared with the already stated objectives. Using the metrics already deployed, the team monitors the process to verify the expected improvement. Phase 5- Control: In the Control phase, the Six Sigma team selects and implements methods to control future process variation. These methods could include documented procedures or statistical process control methods. This vital step assures that the same problem will not return in the future. With the process completed, the Six Sigma team disbands or if required it again takes the same or other problem to reduce process variation with higher/stringent objectives. Monitoring and comparing is the motto of this phase otherwise there lies the threat that the process may slip to its original state. Fig. 1 Six Sigma Roadmap (general) in an Institute IV. PRODUCT (STUDENTS) QUALITY ISSUES In the study of quality management, customer satisfaction and business competitiveness of educational institutes there are a number of attributes of educational institutes that differentiate educational institutes from service and manufacturing. These may be categorized as follows: 1. Identification of “defects” and, those are critical to quality: a. What constitutes a defect or defective could be very personal and hence subjective. b. Delays are common in the recognition of defects or defectives. c. A defect or defective is often more readily noticed (and seems more critical) than a “good” outcome. d. Level of quality tends to be measured and compared via a negative scale (e.g. DPMO (defects per million opportunities), instead of yield; complaints about educational system and facilities tend to be more attention-catching than compliments). 2. Nature or basis for improvement: a. In a given study, the process in question can be, and often is, more relevant or felt more important than the product. b. An instance of service tends to have to be highly customized for all the students (like standardization or mass production in manufacturing). c. The role of raw material, that is input students and faculties, is usually high. d. Inventorization, i.e. accumulation of services, is normally not done. 3. Feasibility of applying analytical tools: a. Standardization, calibration and benchmarking could be inadequate, difficult, or sometimes impossible. b. Product quality relates much more with information flow and utilization than what many traditional quality practitioners are used to. c. Available information tends to be quantitative (i.e. continuous or measured data) rather than qualitative (i.e. discrete or attribute data). d. Educational systems do not lend themselves readily to data-intensive methodologies such as those entailed in Six Sigma. 4. Situation or institute specific issues: a. Specification limits or tolerances not only tend to be arbitrary or impossible, it could also be location/society-dependent and time-varying. b. System boundary could be difficult to draw in a study; noise is usually large and, by definition, and nearly not controllable. c. Customers themselves could be voluntarily or involuntarily involved in the way service is generated. d. Cultural factors, values and ethics could be involved in judgments. Thus a person familiar with manufacturing process studies has to adopt a very different approach when it comes to educational systems. Most educational systems are in need of improvement in the sense of a Kano quality system -- Kano (1984) -- rather than
  • 4. International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470 `@ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 1 | Issue – 6 | Sep - Oct 2017 Page: 980 reduction of DPMO: in fact coupled with human emotions, sentiments and expectations, it is near impossible to define flawlessly a “defect”. V. ANALYTICAL ISSUES When educational institutes’ wants to apply Six Sigma in their organizations, the greatest difficulty or barrier comes from the individuals having higher qualification and experiences with strong desire to sit on higher positions with no knowledge of the processes and their impacts. They fail to answer what is required to be done? How it is to be done? And what will be the output exactly? They try every body part other than the ‘soul’. Energy is wasted in undoing what they have previously done in conventional manner. The original Six Sigma methodology was motivated by arguments based on a normal distribution. All the concepts of 3.4 dpmo as a bench mark, z scores, short-term and long-term performances and so on, are derived and extended based on normal distributions. While the behaviour of many natural physical quantities can be approximated by the normal distribution, the same cannot be said of common educational systems; for example the Poisson distribution is more likely to be appropriate to describe lapses in a specific type of service. With the collapse of the normal distribution background, the idea of “sigma level” as a proxy for “quality level”, with the attendant arguments about improvements, comparisons and so on, is no longer valid. Thus a Six Sigma project cannot be based on concepts of “sigma level” without checking the behaviour of background data. Even if the normal distribution is a reasonable approximation, there are still arguments against the non-linear nature of “improvement”; for example the dpmo reduction for a change from five sigma level to six sigma level is very different from a change from two sigma level to three sigma level. Other controversies, such as the rationale for 1.5 sigma shift in the long term, also carry over from the study of manufacturing systems to that of educational and other service systems; the justifications are, if anything, even more uncertain or unconvincing in the latter. What is even more challenging, from a statistical modelling point of view, is that many educational systems tend to be time-variant owing to changing expectations, lifestyle, culture, demography, political decisions, and so on. Assumptions about noise behaviour, often taken for granted in the modelling of manufacturing processes, cannot be made lightly: For example, data independence is an important yet often ignored requirement in system modelling – as a result of the shallow Statistics training or knowledge of some practitioners. Merely collecting data is not quality. VI. INSTITUTIONAL ISSUES A common desire of management is to attain the highest quality and achievements. They want to know about Six Sigma as they have heard it from so many sources and from media publications also. Some were promised by so called educational consultants that each project would attract flock of students and lacks of rupees. The usefulness or otherwise of such “motivation” is obvious if it is realized that not every organization operates in the same scale, same structure, same product (students) or same input (fresher). The ‘environment’ is ‘different’. All these exciting claims are often repeated in brochures and manuals selling Six Sigma courses which by the way are often expensive, and as a rule training or consulting fees are expected way before any real savings are realized by the clients. All these point to the need for a proper understanding of the principles and rationale behind Six Sigma before its adoption. Six Sigma is not a fad, and educational institutes should not go for it simply because the competition has it, some learned people talk about it, and they themselves feel that this is perhaps good public reputation. Institute needs to create a Six Sigma team as roadmap shown in figure 2, with rights and responsibilities given to it. The Six Sigma team will then be responsible for the way the project carried out in the institution. Institute has to select, train and motivate people in the institute for the success of the Six Sigma project. Institutes following norms of Governing body completely may find it achievable if approached properly for it. Another possibility is to keep unrealistic expectations after hearing the propaganda from incompetent or irresponsible consultants, trainers and faculty members: disillusionment about Six Sigma after payment of hefty amount and deploying expensive manpower in vain would double the pain. To claim that Six Sigma can only lead to business success for any organization is just being irresponsible.
  • 5. International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470 `@ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 1 | Issue – 6 | Sep - Oct 2017 Page: 981 Fig. 2 Six Sigma Roadmap (local) in an Institute VII. PERSONAL ISSUES Educational organizations requires individuals those can give output. Merely having eligibility does not mean the individual is suitable for the Six Sigma project. Then who can decide the right person? Overly optimistic thinking about individuals could lead to disillusion in ways as explained above, but the tendency today seems to suggest that it is not organizations, but rather individuals, that are keen about Six Sigma. Witness the advertisements for training courses for “Belts” of all sorts of colours – of course Black Belts in particular. Almost all such advertisements promise certification: certification of the individual as, for example, Black Belt, rather than an organization. This is in fact a deviation from the original motivation: to improve organizational performance and increase customer satisfaction. It is a fact that nowadays many people sign up for Six Sigma training not necessarily motivated by the operation of the company, but by the certificate that they themselves could possess at the end to improve their CV. Most training and certification programs also require demonstration of competence via a presentation on projects, which not infrequently then lead to some sort of “reverse engineering” – armed with final solutions and results, the “problem solving” or “improvement” process is developed backwards so that the resulting material would fit the expectation of the certification examiners, in a format that inevitably ends with “all is well”. This is not to suggest a termination of the existing Six Sigma training and certification system. What is needed is an ability to avoid not seeing the forest for the trees, and a serious attitude toward Six Sigma projects. There is no rule that says all such projects must end in “all is well”. It is “statistical thinking” that is called for in the execution of projects, and the thoroughness of its application determines the merit of the work. If this point is not appreciated, more individuals will engineer projects “suitable” for certification purposes, but the resulting Black Belts or Green Belts cannot be expected to be able to handle uncertainties of educational systems intelligently and bring credit to Six Sigma. VIII. CONCLUDING REMARKS Engineering educational sector is nowadays a lucrative business as it is playing important role in the economy of a country. At the same time this sector is constantly searching for better tools for improvements. Six Sigma is one such tool which offers various gains not certainly possible by others. In this hope these organisations trying for Six Sigma and at the same time it is presenting considerable challenges to those who apply it. In this paper, a counter point is shown between education, service and manufacturing, followed by discussions concerning the application of Six Sigma at the analytical, institutional and personal levels. There are varying degrees of “goodness of fit” of the descriptions when it comes to individual cases, but universal applicability is by no means implied. As the Six Sigma methodology evolves and as more training and certification programs emerge in the commercial world, it is important that a rational perspective be maintained before investments are made in Six Sigma by an organization for its deployment, or by a person for whatever manner of “certification”, as unrealistic expectations could only lead to disillusionment. It is worthwhile noting that Six Sigma has been largely propagated outside academia and embraced by industry, which gives it a practical bent but would also mean that occasionally insufficient attention is paid to the related theoretical underpinning. The enthusiasm that is seen nowadays for personal certification is necessary but by no means sufficient to spread the effective practice of Six Sigma especially in educational systems. Indeed it must be said that it is only an organization with a critical mass of individuals with statistical thinking, not some certified individuals more concerned with their qualifications than customer benefits, could bring the true power to the educational institute. REFERENCES 1) Arun Vijay S. (2013). “Appraisal of Student Rating as a Measure to Manage the Quality of Higher Education in India: An Institutional Study Using Six Sigma Model Approach,” International
  • 6. International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470 `@ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 1 | Issue – 6 | Sep - Oct 2017 Page: 982 Journal for Quality Research 7(4), ISSN 1800- 6450, pp. 493–508. 2) Dragan Pavlović, Milena Todorović, Srđan Mladenović and Peđa Milosavljević (2014). “The Role of Quality Methods in Improving Education Process: Case Study,” Serbian Journal of Management 9 (2) (2014), pp. 219-230. 3) Arun Vijay Subbarayalu, Ahmed Al Kuwaiti (2017). “Development of a Six Sigma Rating Scale for Measuring the Quality of Work Life of Teaching Staff Working in Saudi Universities,” International Journal for Quality Research 11(2), ISSN 1800-6450, pp. 397–418. 4) Mukondeleli .G. Kanakana, Jan H.C. Pretorius and Bernard J. van Wyk (2012). “Applying Lean Six Sigma in Engineering Education at Tshwane University of Technology,” Proceedings of the 2012 International Conference on Industrial Engineering and Operations Management Istanbul, Turkey, July 3 – 6, 2012, pp, 211-220. 5) Isam Elbadawi, Mohamed Aichouni and Noor Aite Messaoudene (2016). “Developing an Innovative and Creative Hands-on Lean Six Sigma Manufacturing Experiments for Engineering Education,” Engineering, Technology & Applied Science Research Vol. 6, No. 6, 2016, pp. 1297-1302. 6) Sylvie Nadeau (2017). “Lean, Six Sigma and Lean Six Sigma in Higher Education: A Review of Experiences around the World,” American Journal of Industrial and Business Management, 2017, 7, ISSN Online: 2164-5175, ISSN Print: 2164-5167, pp. 591-603. 7) Abhijith.R, Akhil.BS, Sivaprakash.SC and Anshadh.A (2016). “A Study of Current Engineering Education System Under Kerala Technological University Using Six Sigma Method,” International Journal On Engineering Technology and Sciences – IJETS™ ISSN (P): 2349-3968, ISSN (O): 2349-3976 Volume III, Issue III, March- 2016, pp. 52-56. 8) L Ramanan, Dr M Kumar and Dr Kpv Ramanakumar (2014). “SIX SIGMA - DMAIC Framework for Enhancing Quality in Engineering Educational Institutions,” International Journal of Business and Management Invention, ISSN (Online): 2319 – 8028, ISSN (Print): 2319 – 801X, Volume 3 Issue 1, January 2014, pp. 36-40. 9) Majid Shoeibi & Elmira Zahmatdoost (2015). “The Role of Six Sigma in Improving the Quality of Higher Education Institutions,” The SIJ Transactions on Industrial, Financial & Business Management (IFBM), Vol. 3, No. 6, ISSN: 2321- 242X, June 2015, pp. 93-98. 10) Naveen Kumar and Dr. R.M.Belokar (2015). “Six Sigma in Education System: A Review,” International Journal for Scientific Research & Development, Vol. 3, Issue 03, 2015, ISSN (online): 2321-0613, pp. 3504-3507. 11) Marcos Buestan, Cinthia Perez and Edwin Desintonio (2016). “A proposed framework for implementing Lean Six Sigma methodology in Ecuadorian Children Hospital,” 14th LACCEI International Multi-Conference for Engineering, Education, and Technology: “Engineering Innovations for Global Sustainability”, 20-22 July 2016, San JosĂŠ, Costa Rica, pp. 1-7. 12) Sarath Sankar.R.U, Anshadh.A, Akhil.B.S and Abhijith.R (2016). “Stress Analysis of Engineering Graduates Using Six Sigma Methodology,” International Journal of Research in Mechanical Engineering, Volume 4, Issue 3, May-June, 2016, ISSN Online: 2347-5188, Print: 2347-8772, pp. 159-164. 13) Mira Lalovic, Richard L. Shell and Ali A. Houshmand (2002). “The Use of Six Sigma to Improve the Quality of Engineering Education,” Proceedings of the 2002 American society for Engineering Education Annual Conference & Exposition, pp. 7.1195.1-7.1195.18. 14) Mr. Sean P. Goffnett (2004). “Understanding Six Sigma: Implications for Industry and Education,” Journal of Industrial Technology, Volume 20, Number 4, pp. 02 – 10. 15) Issa bass and Barbara Lawton (2009). “Lean Six SigmaUsing SigmaXL and Minitab,” Mc Graw Hill, ISBN: 978-0-07-162621-7. 16) Tannu Vats and Sujata (2015). “Lean six sigma model to improve student performance,” International Journal of Computer Science and Technology, IJCST Vol. 6, Issue 2, April - June 2015, ISSN : 0976-8491 (Online). 17) Chakrabarty, A., and Tan, K. C (2006). “Applying Six-Sigma in the Service Industry: A Review and Case Study in Call center services,” 2006 IEEE International Conference on Management of Innovation and Technology 18) Deshmukh, S.G., N. Seth and P. Vrat (2005). “Service Quality Models: A Review,” International Journal of Quality & Reliability Management, Vol.22, No.9, pp. 913–949, 2005. 19) David Fogarty (2015). “Lean six sigma and data analytics: Integrating complementary activities,”
  • 7. International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470 `@ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 1 | Issue – 6 | Sep - Oct 2017 Page: 983 Global Journal of Advanced Research, 2015, Vol- 2, Issue-2, ISSN: 2394-5788, pp. 472 -480. 20) Prof. Thong-Ngee Goh (2012). “Some practical issues in the application of lean six sigma to service systems.” Nang Yan Business Journal – 1.1, 2012, pp. 21-26.