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Is Six Sigma Still Relevant Today?

2/28/2020

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When you have a business, then it is likely that you have been reading about Six Sigma. However, and since this approach has been being applied for such a long time, you may b wondering if it is still effective.

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Six Sigma

​Besides, as it happens with everything in life, it's hard to please everyone. And Six Sigma is no different. The truth is that there are many critics who have been questioning the wisdom of relying a lot on Six Sigma. Joining these critics are business owners who have failed to implement this approach within your organization.
​


​A Brief History Of Six Sigma

In case you don't know, Six Sigma started being discussed in the 1980s and many manufacturers started applying it right away as a way to reach the zero-defect ideal.

When you look at Six Sigma at a high level, you need to keep in mind that it uses the DMAIC (define, measure, analyze, improve, and control) cycle to eliminate process variation. This way, you should reduce product defects since you are making all processes predictable and consistent. Obviously, this would lead to substantial cost quality reductions for the ones implementing it.

Check out this brief introduction to Six Sigma.

The reality is that when multi-billion dollar companies decided to use Six Sigma within their organizations, these companies were able to save billions of dollars.
Brief History Of Six Sigma

​Statistically speaking, a Six-Sigma level of quality should theoretically achieve 99.9997% yield and equate to 3.4 defects per million opportunities. If these numbers make you raise an eyebrow and wonder precisely where these figures come from, you are not alone in your skepticism. Without delving into the intricacies behind the mathematics too deeply, Six Sigma statistical methods hinge on a standard deviation of plus/minus 1.5, the "Six-Sigma shift." As such, the fundamental veracity of its statistical presumptions has been questioned time and time again.


​The Main Criticisms Of Six Sigma Today

Main Criticisms Of Six Sigma Today

While many companies (both large and small) have already experienced success when they implemented the Six Sigma method, the reality is that not all have succeeded. And there are some main criticisms that are made to the Six Sigma approach.


The main criticisms of Six Sigma today include:

#1: Six Sigma as a one-dimensional philosophy:

According to this argument, the cost reductions that Six Sigma allows are too narrow. Besides, it also includes the fact that not all quality management woe can be separated in terms of quality metrics.

These are the basic Lean Six Sigma metrics.

#2: Six Sigma as a short-sighted business approach:

According to this critic, and even though most business owners agree that Six Sigma can bring cost reductions in the short-term, it is also true that in some cases it may lead to a proverbial wall. ​

#3: Six Sigma as an outsourced service:

The last main criticism made to Six Sigma is the fact that it only serves to hire outsourced companies and individuals who need to be certified as Black Belts or Master Black Belts. And this can be a very problematic process.


Discover why you should get Six Sigma certification.


​Is Six Sigma Still Relevant Today?

In our opinion, yes, Six Sigma continues to be incredibly relevant nowadays. And the main reason is due to the fact that any new manufacturer (or quality manager) hopes to gain credibility as a high-quality business partner. Besides, its continuous improvement philosophy aligns with ISO 9001 standards well. However, it needs context. After all, we also believe that Six Sigma isn't applicable to every quality issue. ​
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The Tools Of Lean Six Sigma

2/28/2020

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As you already know, Lean Six Sigma is the fusion or combination of Lean Manufacturing with Six Sigma. his complex system goal is to allow you to remove wastes and reduce process variation for streamlined manufacturing and optimal product output.

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Lean Six Sigma

​One of the things that you need to keep in mind about Lean Six Sigma is the fact that it uses Six Sigma processes and methods as the backbone of the system to drive focused improvements in manufacturing while incorporating many techniques and tools from Lean to reduce wasteful steps and processes.

The Tools Of Lean Six Sigma

#1: The 5 Whys:

5 Whys

The 5 Whys is the first tool of Lean Six Sigma that you will need to use. The goal is to ensure that you can determine the root of problems within your organization. 


Ultimately, you will need to start by writing down the problem you're having so that everyone in your team can focus only on it. Then, you will need to ask why it occurred. Notice that in case the first answer you get isn't the root of the problem, you will need to ask for it up to 5 times.

Understanding the 5 Whys.


​#2: The 5S System:

5S System

The 5S System is another method of Lean Six Sigma that you can use to organize your workplace materials. This way, they will not only be more accessible as well as the maintenance will be easier. 


Notice that this system is crucial to eliminate waste within your organization. 

Simply put, the 5S's refer to:

  • Seiri (Sort) – Remove all unnecessary items for your current production, leaving only what is necessary.
  • Seiton (Set In Order) – Organize remaining items and label them accordingly.
  • Seiso (Shine) – Clean and inspect your work area and everything in it every day.
  • Seiketsu (Standardize) – Write out your standards for the Sort, Set In Order, and Shine steps above.
  • Shitsuke (Sustain) – Apply the standards you’ve set for your company and make them habits for everyone in your organization.​

Discover the 6 big losses of lean manufacturing tools.


​#3: Value Stream Mapping:

Value Stream Mapping

Another tool of Lean Six Sigma that you can use is value stream mapping. 


Simply put, the value stream map shows you the flow of information and materials in each one of your processes. This allows you to get a better perspective of your workplace and improve and optimize this flow throughout your organization. 

Keep in mind that the value stream map should allow you to easily identify the value-enabling activities, the value-adding activities, and the non-value adding activities. 

The goal of this tool is to eliminate all the non-value adding activities as well as eliminate all the wait times between consecutive steps in your processes. 

Why should you get a Six Sigma certification?


​#4: Regression Analysis:

Regression Analysis

Simply put, a regression analysis is a statistical process that allows you to estimate and understand the relationship between different variables. 


The truth is that when you graph these inputs and outputs, you will be able to visualize patterns that you wouldn't see in another way. ​
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