Six Sigma Process Simulation And Modeling

Six Sigma has become a buzzword in industry circles since its introduction in the 1990's. The methodology is based on a disciplined and data driven approach and is used for eliminating defects and achieving near perfection by restricting the number of possible defects to less than 3.4 defects per million. It is being used effectively for managing processes of both, manufacturing and services industry. In the manufacturing industry, it is used for limiting defects in the goods produced whereas in the services sector it is used mainly for reducing transactional errors.

What Is Process Simulation And Modeling?

Simulation software based on Six Sigma methodologies can be used for simulating a wide range of processes in order to eliminate common industry problems related to defects, wastage of productive resources, and quality control. The basic idea governing Six Sigma process simulation is to provide an accurate system of measuring defects in a process, so that these can be eliminated during the actual production. The emphasis is on measurement and statistics for ensuring that the process is properly set up and measured. The methodology is also used for measuring baseline performance, which helps predict the effects of any improvements made in the process. Proper application of Six Sigma methodologies leads to tangible improvements effected by decisions that have been explored and proven in detail.

Scope

The Six Sigma philosophy covers different aspects of industrial processes ranging from pure defect management to process performance improvement. With the increasing use of Six Sigma methodologies, it has become widely accepted that process simulation and modeling techniques can be used for improving almost any type of manufacturing or transactional process. Most of the process simulation and modeling techniques are based on DMAIC (Define, Measure, Analyze, Improve, Control). In the 'Define' phase, the process simulation techniques are used for identifying the changes that would have made the most impact on the outcome. This helps in making the most appropriate changes. Various simulation tools are used throughout the other phases for providing detailed statistical data on the effect of any proposed changes related to throughput, utilization, delays, service levels, and any other factors related to the process.

How The Simulation Model Works

- The simulation software coverts numerical data into graphic representations, which are relatively easier to understand. - Commercial companies that specialize in providing Six Sigma services offer customized services, wherein the simulation model is an exact replica including all the elements used in the actual process such as machines, labor, conveyor and belts. - All these elements are represented by icons and once they are in place, one can define the link between these elements, establish the process flow, and add as much detail as possible for simulating the actual process more accurately and more effectively. - After setting up the simulation, one can simulate an infinite number of hypothetical scenarios both positive and negative that might affect the process. For example with the help of simulation, a manager can know exactly what will happen if a crucial machining tool breaks down or half the labor force does not turn up for work. - All these factors can severely affect production. However if the extent of potential damage is known beforehand, appropriate contingency plans can be put in place for restricting or even eliminating the possible loss of production.

Process simulation and modeling techniques help executives make informed decisions. The data generated by the simulation tools empowers decision makers with a deep insight about the process and procedures, allowing them the ability to make the necessary changes.

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

Motorola Six Sigma Improvement, is About Training

Among the main issues on the minds of today's business execs is to achieve better results from the business. To obtain these coveted business results and improvements in the performance of the company, a focus needs to be placed on the Motorola Six Sigma training in corporations and businesses of all sizes.

This is contrary to what traditional methods have dictated. Though indeed, training is a desirable element within a business, with cost cutting at such a priority, training is usually one of the first things to go, in order to make room for other more "important" priorities.

With Motorola Six Sigma, on the other hand, the focus is on achieving success by improving the process of the performance of the business. Essentially, by bettering the process, the bottom line improves accordingly. This is done by using a project-by project technique for betterment where the projects are each individually linked to the priorities of the specific business.

This augmentation in the quality of the process relies heavily on the Motorola Six Sigma training, which is specifically designed to provide managers, Black Belts, and Champions with the skills and knowledge that they required for implementing the Motorola Six Sigma approach to each project.

Indeed, the Motorola Six Sigma training can be rather expensive - as training itself is a rather costly element, hence its quick removal from traditional business budgets - however, it has the ability to rapidly pay for itself. In fact, often, it takes only a single project to more than pay for the training of a company's Black Belt.

The time involved in training for Motorola Six Sigma is usually between two and three days for managers, two to five days for Champions, four weeks for Black Belts, and two weeks for Green Belts. Over time, the amount of training will need to grow beyond the initial amount of time.

The result of this training in Motorola Six Sigma throughout the company, however allows for a strong infrastructure development among the managers, champions, Black Belts, and other team members. Each of these individuals will be empowered with the knowledge and abilities for using the Motorola Six Sigma approach to improving each of the processes within the business for improving the results at the bottom line.

Though the cost of training has always been one that companies have struggled to incorporate in their budgets, especially when times are tough, Motorola Six Sigma should always be welcomed as an investment in the future of the business that will ensure dramatic and desirable results.

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

Career as a Six Sigma Professional

Job pages in newspapers and on jobsites clear doubts in anyone's mind about Six Sigma career opportunities. As companies place emphasis on quality and cost management with process improvement being the underlying foundation, Six Sigma is coming to the forefront because of its overall applicability in a business environment. With it comes an upswing in the demand for Six Sigma professionals.

Career Opportunities

Career opportunities are on the rise in the Six Sigma sector at various capacities. For experienced professionals, launching their own venture can also be very lucrative. However, job opportunities probably exist within your organization as well as outside of it.

Within Your Organization

You can enhance your career within your own organization as a black belt or a green belt in Six Sigma discipline by appropriate Six Sigma training. Organizations that decide on Six Sigma implementation usually hire a professional in consultative capacities for initiation. They will not be playing decision-making roles for strategic reasons. Upper management obviously prefers to use its own employees at all levels beginning with green belts at execution levels, black belts at problem solving levels and master black belts at the highest levels.

Outside Your Organization

A keyword search for "Six Sigma" in any of the popular job portals reveal the number of available jobs and related information like the level of employment, salary etc. Both freshly trained as well as experienced black belts are in demand; however, the ratio seems to be slightly skewed in favor of those having implemented at least one or two projects. Certain companies place more weight on prior work experience in a relevant field even with freshly trained candidates.

Another interesting statistic is that black belts are in a rather higher demand than green belt Six Sigma professionals. This is obvious from the fact that, as green belts form the lower rungs of implementation program, they have the obligation of having to divide their time to their routine work as well. It is normal practice to identify people from within the organization for this position.

Six Sigma Training

One unfortunate thing about Six Sigma training is that the methodology is not universal and not standardized. Because of this, there is an inconsistency in teaching, subject material etc. It is important for organizations to confirm through references, employment bureaus/counselors and future employers who recognizes which institute. The fees are another major cause of concern for many candidates.

Many corporations have in-house training facilities for their employees. Candidates may need to undergo Six Sigma training as a condition their continued employment. Some professionals see this as detrimental to their career prospects due to the heavy workload involved.

Aptitude Of A Six Sigma Professional

Black and Green Belt candidates must have open minds and strong analytical abilities. They must possess the ability to question all things with a view to making a core contribution. Above all, self-confidence and a high degree of motivation are necessary. Black belts need to focus more on the analytical and problem-solving aspects and dedicate 100% of their time to the implementation. Green belts can't dedicate 100% of their time, as they have to also focus on their routine responsibilities within the organization. What is expected of them is studiousness, flexibility, understanding of statistical tools and interpersonal skills.

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

Statistical Software in Six Sigma

Six Sigma is about numbers. Six Sigma produces a flood of data about your process that are critical to your success. If you don't measure it and understand what you are measuring, you can't manage it. Six Sigma's clear strength is a data-driven analysis and decision-making process -- not someone's opinion or gut feeling.

The value of statistical analysis cannot be underestimated. Through an analysis of all of that data, you begin to understand your process and develop methodologies to identify and implement the right solutions to improve your process. Statistical evaluation of the data identifies key areas which can have an adverse effect on product quality if not controlled. Once you have identified these key areas you can focus your process improvement efforts

Given the importance of intelligently handling all of this data, you need to find an efficient and powerful method of crunching the numbers. Naturally, you want to avoid the drudgery of manual calculations and save a whole lot of time by using a statistical software application. You may be tempted to use Excel or another spreadsheet application as a calculator and database to store your statistical process control data. However, you will quickly find out that a basic spreadsheet is too cumbersome to handle the volume and sophistication of the data keeping and analysis you need to perform in a Six Sigma project.

Advanced statistical software such as Minitab (http://www.minitab.com/) or Statgraphics (http://statgraphics.com), are very useful if not essential for gathering, categorizing, evaluating, and analyzing the data collected throughout a Six Sigma project. Both Minitab and Statgraphics are powerful full standalone statistical process control software applications for performing statistical analysis. Both are highly recommended for Six Sigma use as they are tools that can help you utilize one of Six Sigma's biggest advantages: the ability to make better decisions based upon data. They will work with the DMAIC Define-Measure-Analyze-Improve-Control methodology and Lean Six Sigma.

Both Minitab and Statgraphics are designed to support the Six Sigma philosophy offering a range of tools for graphical analyses, collecting powerful statistics, quality analyses with potential for a range of custom designed uses.

• Statistical Process Control Charts
  
• Analysis of Variance and Regression Analysis
  
• Design of Experiments
  
• Factorial and Matrix Plots
  
• Relationships between variables
  
• Life Data Analysis and Reliability
  
• Process Capability Analysis
  
• Hypothesis Testing
  
• Correlation and regression
  
• Time Series Analysis and Forecasting
  
• Measurement Systems Analysis
  
• Regression Analysis
  
• Multi-variation analysis
  
• ANOVA tools and techniques
  
• Six Sigma Quality Assessment

Both applications provide you with nearly real time statistical data, enabling you to respond quickly to prevent further defects. Statistical evaluation of the data identifies key areas to focus process improvement efforts on, which can have an adverse effect on product quality if not controlled.

However, while it is easy to purchase a statistical software application, it is harder to use it effectively. It is <EM>smart </EM>analysis of the data that create real change. All too often, Six Sigma/DMAIC teams collect and load data into Minitab or Statgraphics only to find themselves overwhelmed by the prospect of where to start and how to use their new tool to successfully analyze their data that comes up with, not just any answers, but meaningful and useful answers. As a result, Six Sigma/DMAIC projects often fall far short of the productivity expectations associated with statistical software.

Training in use of Minitab is often offered integrated with Six Sigma training. Minitab training will focus on solving practical problems with Minitab. This includes learning the practical aspects of major statistical tools like Control Charts, Capability Analysis, Regression Analysis, and ANOVA. There is a strong emphasis on learning how to get data into Minitab, learning how to manipulate data once in Minitab and learning how to display graphically major findings from the data. Proper training will teach you how to drive Minitab like a pro and thus bring greater statistical power to your Six Sigma projects.

Peter Peterka is President of Six Sigma us. For additional information on Six Sigma Master Black Belt or Minitab Training programs contact Peter Peterka

Keys To Six Sigma Success

Six Sigma delivers but its success hinges largely on the seriousness of the organization. Although, it is not as simple and as this, Six Sigma is gradually following a path that its processors took during their heydays. While it is too early to predict the future of Six Sigma, it gradually is causing fewer eyebrows to raise in boardrooms across the world anymore. We will take an insider look at the causes for this and what keys open the door to Six Sigma success, as both are inseparable from each other.

An Insight Into Six Sigma Implementation

Six Sigma requires the organization restructured correctly from top to bottom. From Champions to Green Belts, people are hired or insiders are trained for specific duties. Personnel at each level of the organization have their assigned and well-defined jobs with varying degrees of authorities and powers so that, apart from executing their routine job duties, they are able to effectively solve problems. This is a sticky issue where powers overlap within executive departments. Unfortunately, at times this causes relationships to sour, however unintentionally. The actions of champions, who are supposed to intervene, can be mistaken for intrusion in cross-departmental matters such as this.

It is here that the success of Six Sigma requires total commitment from upper management of organizations. If the tense atmosphere is not remedied, Master Black Belts or Black Belts can get frustrated and fail to concentrate. Further deterioration, whether because of procrastination on the part of Champions or upper management, brings professionals into the fear zone. Consequently, the Six Sigma implementation suffers. The delay in its implementation adds to the already hefty financial bills with results yet to be realized.

Obviously, this pushes upper management into a corner with few options. With the commitment of upper management being challenged, the vision that the organization had fails to gel with the larger scheme of things.

Key To Successful Implementation Of Six Sigma

More or less, it is slow implementation that throws the Six Sigma vision into question. If the first among these is the miscalculation about the different aspects which include the saving potential and implementation timeframe, the intensity with which the implementation is being made comes in a close second.

The Anomaly Of Limited Savings: It is agreed that Six Sigma implementation is a huge expense to organizations, but if companies adopt stringent accounting practices to calculate savings, with tightening of expenditure as may become appropriate, results can be expected to turn around. The expenditures can be calculated just like capital expenditures, and proper adjustments to future budgets must be made. Failing this, savings in terms of money in such cases cannot be expected to be substantial.

The Intensity Factor: If for any reason, there are less stringent implementation methodologies and the process is pushed through without proper training of professionals, you can expect the results to be mediocre. Compromises give way to a slippery slope and ultimately the failure of Six Sigma.

Tony Jacowski is a certified Master Black Belt for Aveta Solutions – Six Sigma Online ( http://www.sixsigmaonline.org ). Six Sigma Online offers online six sigma training and certification classes for lean six sigma, black belts, green belts, and yellow belts.