Lean Six Sigma Implementation Basics

Lean Six Sigma methodologies are a combination of standard 6-Sigma quality improvement techniques and lean manufacturing principles that are used for speeding up business processes. 6-Sigma methodologies focus on reducing defects in business processes, whereas Lean 6 Sigma does not only eliminate defects but also improves the speed of a process and reduces waste by eliminating non-value added steps in a business process. Combining 6-Sigma and lean manufacturing principles is like combining the contents of two different toolboxes that help companies to improve quality and efficiency.

Compatibility

Depending on the type of methodologies used by an organization, Lean Six Sigma is often referred to as Lean Service, Lean Manufacturing, and Lean Enterprise. These concepts are compatible with standard Six Sigma methodologies and can be applied to every type of business processes. Both the concepts use similar strategies and methods and focus on improving business processes that serve customer needs. Both focus on identifying and eliminating sources of waste and processes that do not add value for maximizing output, efficiency, and throughput. They emphasize providing requisite training for enabling employees of an organization to understand the tools and processes of the methodology. Both concepts encourage the involvement of senior managers and key mentors within an organization for ensuring that quality improvement projects are executed without affecting the day-to-day operations.

Lean 6 Sigma uses different techniques for reducing costs, reducing production cycle times, expanding capacity, and improving productivity. It uses "value stream mapping" for identifying improvement opportunities. However, Lean Six Sigma concepts may sometimes prove inadequate in solving some of the more complex problems that call for advanced analysis.

Benefits

Standard 6-Sigma methodologies follow a disciplined, data driven approach and use statistical tools for analyzing quality at every stage of the production process. When combined with Lean manufacturing principles, it helps in identifying and resolving quality issues. Its successful implementation is important in reaping quick results and enabling employees and plant managers to harness better work patterns on plant floors. Lean Six Sigma programs are executed under the guidance of 6-Sigma Champions and Black Belts for enhancing the efficacy of quality improvement initiatives. It is necessary to deploy lean manufacturing techniques during the Six Sigma implementation process for ensuring that the improvement process includes a standard problem-solving approach.

Lean Six Sigma focuses on adding value to manufactured goods or services rendered by eliminating defects in every business process. This helps in building customer loyalty, as customers often prefer products and services that offer consistent quality. The matrices used in Six Sigma help in identifying customer needs, manufacturing quality products and rendering quality services.

Lean Six Sigma concepts and methodologies are based on a highly sustainable approach that gets easily integrated with the existing work processes within an organization. It requires the involvement of employees at all levels within an organization. The deployment of 6-Sigma programs can initiate a culture shift within an organization that helps in eliminating waste within the production process.

Lean Six Sigma helps in ensuring future success of an organization by radically improving quality and reducing waste. It also allows employees within an organization to design and develop new business processes that will help in making drastic improvements to the organization's performance.

Tony Jacowski is a quality analyst for The MBA Journal. Aveta Solution's Six Sigma Online offers online six sigma training and certification classes for lean six sigma, black belts, green belts, and yellow belts.

Six Sigma Document Control Issues

When discussing Six Sigma document control issues it is essential to recognize the effect Six Sigma has on any firms QS/ISO 9000 initiatives. From its inception until today, Six Sigma has evolved and at present is much more than a defect control mechanism. It is referred to as a methodology that is used to control course deviations that have the capacity to cause defects. In any process where change is initiated, there is often an undesirable variation in end results. The 6-Sigma methodology is intended to manage variation and do away with such expected defects. Its use guarantees superior performance, consistency and value to the end user.

Major Techniques

The two Six Sigma methodologies to be understood are Six Sigma DMAIC methodology (Define, Measure, Analyze, Improve, Control) and Six Sigma DMADV methodology (Define, Measure, Analyze, Design, Verify). What is most important in Six Sigma document control is timely interception and communication. When using 6-Sigma to uphold ISO 9000 certification, document control is an important aspect of the entire process. The Document Control feature is helpful in regulating the known coordinates. Its need arises when changes are made in any regular practice. As and when there is change in a system, it may require a while to understand and adjust to these alterations. Since the authorization to amend standard procedures is often made by an individual or specific body within a company, it is very important that all staff members who will be affected with these changes are notified in time. An accurate control measure guarantees that all personnel who are going to be affected by this interference are made aware of the changes. The document control aspect helps them analyze these changes, as well as realize that the new directives are now part of standard procedures. Document control helps associated personnel adhere, acknowledge and understand revisions in standard practices.

Alternatives

The document control procedures and alternatives have been discussed long enough to rationalize Six Sigma implementation. In most cases, a lot of objective revisions and realization of the need for change is possible through ISO 9000 Corrective Action data evaluations. The alternative is to use a proactive approach when implementing 6-Sigma to help provide greater value to the end customer along with developing a particular company"s reputation and projecting a much needed competitive edge. In Six Sigma methodology implementation, a company"s management selects and sponsors the Six Sigma project that is intended to accomplish planned objectives. As such, a specific project is awarded to a team that has potential process personnel and is led by a certified 6-Sigma Black Belt. Aside from having access to adequate funds needed to work on a new project, the team is also permitted to make authorizations to bring about the required change and implementing the blueprint of the methodology that is chosen.

Advantages Of Document Control

The document control procedures and alternatives ensure that a thorough evaluation has been carried out prior to undertaking any new project. Six Sigma methodology, together with an ISO 9000-type Document Control system avoids negligence of vital factors, provides accurate logistic results, allows for insight into long term project results and prevents process personnel from resorting to any previously used plan of action.

Tony Jacowski is a quality analyst for The MBA Journal. Aveta Solution's Six Sigma Online offers online six sigma training and certification classes for lean six sigma, black belts, green belts, and yellow belts

Company Politics And Six Sigma

No grouping of human beings is without some amount of politics. Managing deployment of Six Sigma in your organization will unavoidably run into some personal issues and conflict. However, with deft handling of the personal and political issues that come up, along with patience and perseverance, your Six Sigma deployment will not get derailed.

Political factors that can affect a Six Sigma project include personal resistance to change, inflexible company policies, and incompatibility with existing organizational methods and goals. Not surprisingly, all of these factors also affect business processes of any kind. They are not unique to Six Sigma. This is one of Six Sigma's strengths: realistically acknowledging the way politics work in an organization. Six Sigma is not just number crunching. It understands the importance of and encourages the involvement of people throughout and at all levels of the organization working together toward a common goal. Six Sigma encourages planning, communication, and openness about processes, procedures, and information.

Many people see change, any change, as loss?a loss of their power or a loss of the security of the old way of doing things. Thus, people are prone to defend the old way, out of habit and out of unease. They wonder how change will affect them and what exactly happens behind the scenes and if they don't know, become apprehensive. This is a problem that can be overcome through communication. Six Sigma successes require clear and open communication at all levels. Any change in an organization will meet some resistance, either intentional or just from inertia. When management can effectively communicate that it is behind that change and can communicate the positive aspects of the change, resistance and ?turf? politics can be countered and overcome.

Another problem is people who disregard the value and power of Six Sigma and consequently, they are reluctant to support Six Sigma projects. To the uninitiated, Six Sigma may appear similar to or simply an evolution of other quality programs. There have been so many quality improvement fads over the years. It is not surprising that people are now a little jaded. Others may see Six Sigma as solely another cost-cutting or productivity enhancement fad. This is a short-sighted view. Six Sigma is neither a fad nor just another quality initiative. It is a ?way of life.? It is a multi-level, cyclical movement toward continual process improvement. The quality improvement fads sell themselves as cheap and easy quick fixes. The reality is that there are no quick fixes to significant process improvement. Six Sigma understands that; it is not a simple quick process. However, the right Six Sigma training and information will help people to understand that Six Sigma is significantly different; it is a robust continuous improvement strategy and process.

Once projects are begun, Six Sigma projects can become a battle of wills for control over which strategy, approach, or tool is used. Team meetings can devolve into arguments over which measurement to use, how it will be calculated, which charts will be generated, whether to use DMAIC or DMADV, etc. Six Sigma is not about making things more difficult. It is about using common sense to make things easier. It is certainly about recognizing that there is more than one road to improvement and more than one right answer to a problem.

In overcoming political problems, the leadership of senior management is critical. Successful Six Sigma programs are built on a solid organizational foundation. The organizational structure and system needs to be clearly identified and communicated to the entire organization to successfully implement Six Sigma Quality. Becoming a Six Sigma organization doesn't just happen. Planning and training goes into setting up a successful Six Sigma organization. Employee roles and responsibilities must be established and clearly communicated to all. For many companies successful in Six Sigma, the key factor has been the direct involvement of their top leaders.

Six Sigma is about getting everyone involved. A Six Sigma project forms a team of people who work together to identify problems and develop solutions. Such teams are not isolated teams rearranging the world for everyone else to live in. These teams are serving the organization by employing the skills and tools they have learned to increase quality and reduce defects. Instilling the team concept along with expert training will go a long way toward solving potential political troubles in your organization. Peter Peterka is the principal Six Sigma Consultant in practice areas of DMAIC and DFSS. Peter has over 15 years experience including implementation of Six Sigma in Healthcare.

Six Sigma and Online Training by Peter Peterka

While nothing can exceed the breadth, depth, and quality of direct in-person training, various factors can make it inconvenient. If your organization is serious about Six Sigma training, but find it difficult to get everyone together for instructor-led training, then an online Six Sigma course is a worthy alternative. An online training program can give your organization more flexibility and even reduce your training costs.

Online training has been shown to be useful for many learning applications and Six Sigma is one of those. The advantages of online training over instructor-led training are simple but profound. There is considerable savings in cost as online instruction is less expensive than in person classroom training and there are no travel expenses. Also online training offers greater flexibility in scheduling and causes less interruption in work schedules.

An online training course combines the advantages of uniformity in training and self-paced training. The basic course is the same for each trainee but can be delivered to different people at different times. While a human instructor is only available a limited time, online training materials don't "go home" and trainees can review the subject matter as needed or desired. Support can be supplied via e-mail or phone. This scheduling flexibility is one of the benefits of online training. Six Sigma courses can be made available for a specific amount of time. For example, you could be granted access to the course material for four weeks which could be extended an additional two weeks on request at minimal or no extra cost.

The electronic format of online training makes it easier to tailor training to your specific needs. Training can be split into modules and you can present different modules to different people in your organization giving them only the training they need to fulfill their role. A Six Sigma online training program can provide an overview of the Six Sigma concepts and tools while going into detailed procedures and knowledge as needed. Those who need the basics of the Six Sigma methodology can receive it in a concise and easy-to-understand format. Those who need more advanced topics such as Six Sigma deployment practices, project development, and the DMAIC problem-solving approach can receive those.

Six Sigma training in an online electronic format focuses on active and applied learning methods where people can interact directly with the material and tools. Trainees are able to view samples of Six Sigma projects including some of the methods used within a Six Sigma project. Trainees can also get hands-on experience using some of the many statistical tools used in Six Sigma. Rather than just hear about statistical methods, they can see how they work in a spreadsheet in front of them. They can play with the numbers and even practice computing for variables to see directly how the tools function.

The online format also gives you more control over the training and greater assurance that your people are achieving each learning objective. Well placed mini quizzes can be employed to check for student understanding and give immediate feedback. Trainees will know in "real-time" whether they understand the concepts presented and the online course can provide repetition of content if needed. Trainees can spend more time on the modules you need. --invest as much or as little time as appropriate for you and not a class on each module.

Online training most likely will not require any additional equipment at your location. Training is delivered through existing computers and an Internet connection. Most online courses will run through any Internet browser on any operating system. You will need to dedicate newer and powerful computers to the training is the course has graphics, sound or video. Don't make the mistake of using old castoff computers as your training computers. That will just make your trainees frustrated.

A well designed Six Sigma online training course can be highly effective. The flexibility of scheduling and content delivery, plus the cost savings make online Six Sigma training either as an addition to or a replacement for the face-to-face classroom environment, a strong part of your organization's Six Sigma deployment.

Peter Peterka is a Master Six Sigma Black Belt for Six Sigma us and has implemented Six Sigma in a variety of organizations. For additional information for Six Sigma Online Training please contact Peter Peterka at http://www.6sigma.us

Peter Peterka is the Principal Consultant in practice areas of DMAIC and DFSS. Peter has eleven years of experience performing as a Master Black Belt, and has over 15 years experience in industry as an improvement specialist and engineer working with numerous companies, including 3M, Dell, Dow, GE, HP, Intel, Motorola, Seagate, Xerox and even the US Men's Olympic Team.

Six Sigma Training 101 Better Management Basics

What is Six Sigma?

Six Sigma is a quality management program that is designed to achieve a six sigma level of quality for products. In the mid 1980s, Motorola pioneered Six Sigma and it has since been adopted by many other companies and manufacturers. Service companies also implement Six Sigma strategies to improve customer service and relations. The idea behind Six Sigma is that failures in quality and customer satisfaction occur after the sixth sigma of likelihood in a normal distribution curve. Hence, the idea is that there are less defects per product or customer service. Motorola defines the success of six-sigma quality in terms of the number of Defects Per Million Opportunities.

Why Use Six Sigma?

Many companies and critics of Six Sigma believed that achieving six levels of quality was impossible, but many companies have proved the critics wrong. Some companies even go beyond six-sigma. An example of this is GE Aircraft Engines, which operate at Nine Sigma levels of quality. Six sigma is practical because it reduces the amount of errors in customer service and products. This leads to increased customer satisfaction, increased revenue, more returning customers, and the acquisition of new customers. Companies that can implement six-sigma successfully have higher standards of quality and usually produce better products and services.

Why is it only Six Sigma?

Many people do not know how six-sigma relates to 3.4 defects per million. Essentially, people do not know how having six levels of sigma improves quality significantly. Many companies used to have less sigma, usually about three or four. However, Motorola was the first to use six levels. Six is the perfect number because whereas four sigma makes sure that there are only about 2.6 problems in a thousand. However, the problem arises with deviation. Imagine a manufacturing process in which a drill makes a hole that is supposed to be 100 micrometers. With four levels of Sigma, only about 1 in 400 will be defective. This unfortunately does not take into account the average value of measurement, which will shift over time. So, if the measurement gradually drifts as each new hole is drilled, about 6.6% of the output will be off by 1.5 sigma in each direction at anytime. If the process has drifted by 150 micrometers, then the hole will be off by 300 micrometers, which is an extremely large defective rate. Using 6 sigma, with a 1.5 sigma shift to make up for average deviation, the ratios are much lower and therefore the defective rates are much more sensible. The same drift in a six-sigma process will still only produce a defect for products or services that are more than 4.5 sigma away from the average in the same direction. Using the mathematics of a normal curve, this works out to 3.4 defects per million which is much more acceptable.

Conclusion

Customers value quality above all other things in a business. If a business produces a high quality product or service, more customers will return, and that business will gain new customers. Six-sigma helps to ensure the quality of goods and services is only the best. Six-sigma, when implemented correctly, is very effective and that is why many companies today use Six-sigma. This process was pioneered more than 20 years ago by Motorola, and has proven its lasting qualities through its continued use in the business world. Any company that wants to gain and retain customers while producing a high-quality product should consider the use of Six-sigma.
Dana Schorden enjoys writing about Six Sigma. Learn more at Six Sigma Weblog ( http://www.sixsigmablog.org/training/), a weblog with daily six sigma training tips and news.

Six Sigma And Healthcare

Six Sigma methodologies aim at improving overall quality by eliminating defects and achieving near perfection by restricting the number of possible defects to less than 3.4 defects per million. Six Sigma methodologies were originally developed for implementation in the manufacturing sector but with time their use has spread to the services sector as well. In the services sector, Six Sigma concepts are used mainly for eliminating transactional errors.

Today, the concepts and methodologies of Six Sigma are increasingly being used in the healthcare industry for improving the quality of services rendered, increasing efficiency, and eliminating human errors that can often prove fatal. However, the use of Six Sigma in the healthcare industry is a relatively new phenomenon as compared to other service industries that have undergone some type of data-supported, systematic, quality-improvement process. With medical and technological advancements, the demand and expectations for improved medical care are continuously increasing. However, due to lack of effective management systems, inefficiency is increasing, which often leads to congested emergency rooms, customer complaints, and lost revenues.

Benefits

Six Sigma concepts and methods enable a healthcare organization to offer improved healthcare services to patients by streamlining business processes. In the healthcare industry, the quality of services rendered depends a lot on human skills, which is often very difficult to measure and control. Six Sigma is effective as it is based on a comprehensive approach that focuses on improving both human as well as transactional aspects of a process. Although implementing Six Sigma concepts in the healthcare industry is a challenging task, it does help in getting quick results.

In the healthcare industry, the factors that determine the quality and efficiency are usually the flow of information and interaction between people. Six Sigma helps in streamlining the flow of information and achieving strategic business results by initiating cultural shifts all throughout the organization. Six Sigma focuses on improving processes rather than just concentrating on the task, which helps in increasing the scope of improvements. It provides the necessary tools and methodologies that help in analyzing and transforming human performance, necessary for achieving significant long-term improvements.

Process

Six Sigma helps in defining a vision for the future, identifying specific goals, and establishing quantitative measures for turning that vision into reality. It helps in formulating goal plans and setting timelines for moving from current performance levels to Six Sigma performance levels. The plans are defined only after documenting their effects on the organization’s work processes’ that may include flow of information, surgical site procedures, handling patients, and others.

The basic requirements for successfully implementing Six Sigma programs are usually long-term vision, commitment, leadership, management, and training. It is important to provide the requisite training to doctors, nurses, and the administrative staff for making them aware about the various concepts and methodologies. The training may initially appear to be expensive, but is often worth the cost when one considers the benefits such as improved quality of services and increased efficiency. It is necessary for employees working in a healthcare organization to develop an understanding about the various Six Sigma concepts. This will help them in integrating new techniques into the Six Sigma processes for improving quality and effectiveness.

Tony Jacowski is a quality analyst for The MBA Journal. Aveta Solution's Six Sigma Online ( http://www.sixsigmaonline.org ) offers online six sigma training and certification classes for lean six sigma, black belts, green belts, and yellow belts.