Six Sigma

Six SigmaJason Cumins

OverviewWhat is Six Sigma?History of Six SigmaSix Sigma MethodologiesThe roles of Six SigmaSix Sigma and CMMIBenefits and Issues of Six Sigma

What is Six Sigma?A quality improvement approach to ANY

company’s product/processData driven approach for eliminating

defectsSix standard deviations between the

mean and the nearest specification limit

What does Six Sigma do?Six Sigma means the process produces

3.4 defects per one million opportunities

Sigma level

Sigma (with 1.5σ shift)

DPMOPercent defectiv

e

Percentage yield

Short-term Cpk

Long-term Cpk

1 -0.5 691,462 69% 31% 0.33 –0.17

2 0.5 308,538 31% 69% 0.67 0.17

3 1.5 66,807 6.7% 93.3% 1.00 0.5

4 2.5 6,210 0.62% 99.38% 1.33 0.83

5 3.5 233 0.023% 99.977% 1.67 1.17

6 4.5 3.4 0.00034%

99.99966% 2.00 1.5

7 5.5 0.019 0.0000019%

99.9999981% 2.33 1.83

History of Six SigmaMotorola 1985GE 1995Extremely popular now

Roles of Six Sigma

Roles of Six SigmaGreen BeltBlack BeltMaster Black BeltChampionSponsor

Green BeltsLowest level of the Six Sigma team other

than team membersLower level management A few weeks of in class trainingIn charge of small projects or part of a

Black Belts project

Black BeltsNext level of the Six Sigma teamTakes on large and difficult projectsAt least a months worth of in class

trainingHelps guide Green BeltsOfficially certified

Master Black BeltsMust be certified Able to train and coach othersGenerally has a lot of experience

ChampionsSenior level executivesSolves issues between Black Belts and

sponsorsMust have a high-level understanding of

Six SigmaActively leads company to fully implement

Six Sigma

SponsorsSimilar to championsSponsor overall six sigma initiative Generally high-level executive

Six Sigma MethodologiesTwo main methodologiesDMAICDMADV or DFSS(“Designs for Six Sigma”)

DMAICUsed for improving existing processGenerally easier projects Uses Green Belts

DMAICDefineMeasureAnalyzeImproveControl

Define“Critical to Quality” areasProcesses that are involvedScopeForm a teamCreate a project charterDetermine requirements

Define Tool (SIPOC)

MeasureCollect data on current processesUnderstand why defects are createdMake sure data is valid

AnalyzeIdentify ways to improve the processFind the root of poor sigma performanceIdentify sources of variationDecide on which areas need to be

improved on

ImprovePropose a large number of solutions Create tests and evaluate solutionsCreate an implementation plan

ControlImplement the plan determined from the

last phaseFocus on maintaining the six sigma

performanceTrain staff in the new process

DMADVAlso known as Design for Six Sigma(DFSS)Similar to DMAIC Create an entirely new processExtremely challengingUses Master or Regular Black Belts

Define, Measure, AnalyzeFirst three phases are the same as DMAICDefine the projectMeasure the expectationsAnalyze the data and figure out

alternative solutions

DesignImplement solutions and create a

prototypeNecessity that critical to quality factors

are accounted forCarry out detailed design

VerifyMake sure Design phase fits all

requirementsCritical to quality areas have great

performance

Six Sigma and CMMIIt is not a competitor to CMMIUse Six Sigma with CMMI can help

improve Maturity levels

Capability Maturity Model Integration (CMMI) OverviewProcess improvement for software

developmentDefined by its maturity levels: Initial,

Repeatable, Defined, Quantitatively Managed, and Optimizing

Direct Correlations with CMMIQuantitative Process Management and

Casual Analysis & Resolution

Integration with CMMIStart using CMMI to create processes

based off the communityImplement Six Sigma to optimizeSix Sigma reinforces mission focus and

extremely supportive of CMMI implementation

Benefits of Six SigmaAverage Black Belt saves the company

$230,000Positive results for Motorola, General

Electric(GE), and Allied Signal/HoneywellExtremely efficient production processRapid process improvement

methodologies

Issues with Six SigmaIf not fully committed it just doesn’t workRequires a large amount of trainingManagers must be active and have the

ability to lead complicated projects

ToolsMinitab 16

◦Minitab 16 Video

Questions?

ReferencesIdeal Meadia LLC. i Six Sigma. Retrieved

3/08/2012. <http://www.isixsigma.com/> Siviy, Jeannine; Penn, M. Lynn; Harper, Erin.

“Relationships Between CMMI and Six Sigma”. Software Engineering Institute 2005. Retrieved 3/08/2012. <http://www.sei.cmu.edu/>

Franza, Richard; Chakravorty, Satya. “Design for Six Sigma(DFSS): A Case Study”. Kennesaw State University, Dept. of Management and Entrepreneurship 2007. Retrieved 3/10/2012. http://ieeexplore.ieee.org/

ReferencesCatherwood, Philip. “Champions of the cause”.

Waterton Technol. Centre, UK 2005. Retrieved 3/12/2012. http://ieeexplore.ieee.org/

Pan, Zhedan; Baik, Jongmoon. “A Six Sigma Framework for Software Process Improvements and its Implementation”. Asia-Pacific Software Engineering Conference. Retrieved 3/12/2012. http://ieeexplore.ieee.org/

Aveta Business Institute. Six Sigma Online. Retrieved 3/14/2012. <http://www.sixsigmaonline.org>