The Cost of Poorly Performing Processes – Need for Six Sigma
February 12, 2025
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Six Sigma is a process oriented methodology designed to improve business performance by improving specific areas of strategic business processes. There are 2 different methodologies available for carrying out improvements in processes or operations.
Improvements can be of two types: improving the existing process or designing a new process altogether. When we have an existing process and we want to improve the process we deploy the DMAIC methodology. While designing a new process or completely revamping the existing process the Design for Six Sigma or IDOV methodology is deployed.
DMAIC | DFSS |
Structured and iterative process improvement methodology | Rigorous approach to designing processes that will exceed customer expectations |
Focus on defect reduction | Focus on defect prevention |
Define | Define the problem. Define the customer(s) and the requirements. Define the current capability. Define the key processes that will have the greatest impact on customer. |
Measure | Identify the statistical measures to monitor the key process. Set up the data collection plan. Measure the process |
Analyse | Determine the analysis tools and methods to be used. Summarize the data measured. Run the analysis and determine the root causes, effects, etc. |
Improve | Improve and Implement. Focus on developing process/technology to improve the root cause. Test the method on sample process and validate the improvement. |
Control | Standardize and document the process and implement the plan. Monitor the process and feedback the results back to the process for continuous improvement. |
Identify | Develop a team. Create team charter. Gather VOC. Perform competitive analysis. Develop CTQs and formally tie design to VOC. |
Design | Identify functional requirements. Develop alternative concepts. Evaluate alternatives and select a best-fit concept. Deploy CTQs and predict sigma capability. |
Optimize | Determine process capability. Develop detailed design elements. Predict performance. Optimize design. |
Verify | Test and validate the design. Share feedback with manufacturing and sourcing to improve future manufacturing and designs. |
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