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

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

Six Sigma & Strategic Planning

Strategic planning, as applied to Six Sigma, implies that the drawing down of elaborate and systematic planning of areas of concerns that have far-reaching and tactical implications at the project selection stage. The purpose of strategic planning is to have produced fundamental decisions and actions that guide successful Six Sigma implementation.

An Overview Of Strategic Six Sigma

Many CEOs are skeptical about the outcome of Six Sigma, despite huge annual spending. A critical component which helps integrate the visions of the leader with the functioning of the organization is strategic programming derived from "strategy deployment mapping". This is said to produce an entirely new direction for the organization. The skepticism about the vision of building a future begins to gain momentum with the linking of visions to action plans and when it delivers tangible results. Six Sigma takes strategic planning to a different plane of thinking by delivering on this promise.

Success Begins With Planning

It should not be forgotten that the foundation for success is proper and adequate planning. Planning is the elaborate statement of vision by the leader of the company. This is true for both large corporations and smaller start-ups. The core of transforming organizational vision into tangible gains by employees has many steps to overcome obstacles on the path to achievement. Achievements will have to be translated to customer satisfaction for Six Sigma to be successful.

Sharing Of Vision

The vision which begins its journey with upper management needs to be shared by all the stakeholders. It may be difficult to demonstrate to employees that their actions relate to customer reactions directly. Another missing link that needs to be connected is the customer himself. The emphasis of Six Sigma is on factoring in customers & engaging them in defining needs. Deploying employees actively connects these disjointed needs. The powerful tools of Six Sigma highlight and simplifies the linkage between key elements, activities, strategies and finally the vision, paving way for smooth sharing of ideas. The methodology of Six Sigma communicates company vision effectively to all concerned in a language understandable by each of them.

Critical Mass

There is also a danger of leaders getting bogged down by trivial matters of day-to-day operations and numerous details. Two of the tools of Six Sigma (metrics), key requirements and differentiators, come to the rescue. These two metrics highlight the importance or irrelevance of some data and push for excellence on those that matter. The end result is helping leaders to envision the strategic importance of activities and steering clear of trivial, mundane things.

Deployment of Six Sigma can't be disconnected from strategic planning and financial activities, either. If the decision to implement Six Sigma is a result of strategic planning, it means the leadership has recognized the need for complete retooling of the organization, no matter what phase it is in.

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

Six Sigma Certification

Many questions arise in the minds of six sigma certification candidates. These questions range from the most strange to the most genuine concerns. There is a compelling need to explain things regarding the exam for the benefit of those who have questions but don't know where to find the answers. Here is brief outline of a few fundamental questions that are frequently asked about Six Sigma Certification.

What Is Six Sigma Certification?

Six Sigma Certification is documented proof that a person has acquired certain standardized capabilities with regard to the quality management technique that, when applied, works towards error/defect elimination and prevention. However, the certificate does not guarantee that a candidate has implementation skills, but only certifies competency in the subject matter. One can attain certification in any of the key roles (Master Black Belt, Champion, etc.).

Basis For Six Sigma Certification

Six Sigma Certification typically involves studying the related subject matter and passing an exam. Training institutes or companies provide certification tests and six sigma training courses. It is not unusual for new companies to have their employees test on a training institutes' tests. This completes the first part of the written test in the candidate's proficiency in the subject matter. Now comes the real test! Once having passed the written test, The candidate must work hands on a project or two in a practical environment. In this situation, the candidate must demonstrate that he or she is competent enough to implement the knowledge acquired in classroom six sigma training.

During the practical part of the exam, there is no benchmark for what passes or not. Not just this, but some companies may accept just one project and some others may not. This means that out of the three critical aspects of six sigma certification training, the written exam and the practical competency demonstration, a crucial third one may be said to be lacking seriously or non-existent, unless it becomes standardized. To complicate matters, there is no one single body to regulate or standardize all the critical aspects of six sigma certification.

Do I Need A Six Sigma Certification?

This is any individual's professional decision. Anyone wanting to get six sigma certification will need to think seriously about it. Sometimes candidates are chosen (or compelled) by their employer to take six sigma training and thereby attain six sigma certification. But many times, it is the other way around. Someone may decide to pursue six sigma certification for reasons such as attainment of a raise or promotion. Another may be prompted by the fact that six sigma certification will enhance their marketability. While each reason is an individual one, candidates must be result oriented, highly motivated in order to be successful.

What Will It Cost Me?

Again, this is a highly subjective question. It could cost you anywhere from $0 to $30,000 per person, depending on where you receive six sigma training. Again, the decision as to the trainer, location, and online or offline six sigma training method are other considerations as to cost.

What worked for one person may not work for another. When contemplating six sigma certification, there really are no generalizations that can be made. It all depends on who individual capabilities, location, and to some extent, your position in the corporation (or lack thereof).

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

Six Sigma Defined - Praises and Criticisms

Consumer outlook has undergone considerable changes due to business globalization and revolutionary information exchange paradigms. Changing business conditions created by the flurry of increasing competition has led to diminishing margins for error. Exceeding the expectation levels of customers assumes the central position in the current and future era of business. It is for this reason that Six Sigma has assumed critical importance in the current business environment.

What is Six Sigma?

Six Sigma is a two-way quality management approach towards achieving zero errors by removing process defects for existing products and by designing verified process flow for new products. From a consumer's point of view, Six Sigma is a highly disciplined process that enables product and service deliveries to a near perfect standard.

The term Six Sigma (also 6 sigma) signifies the statistical benchmark for quality assurance. Sigma is the standard deviation (allowable, standardized figure from the mean acceptance level), and when the measured number of deviations beyond the mean tolerance limit is six, you are barely producing quality products. Simply put, this means that if you found six defects in your products, you are very close to poor quality production.

Implementation Of Methodology

The choice of implementation of Six Sigma methodology depends on whether improvement is required on existing processes (DMAIC) or on new process/product design creation (DMADV).

DMAIC

In Six Sigma, DMAIC methodology involves defining improvement goals, measuring the existing standards at baseline for future reference and analyzing the relationship between defects and their causes. This Six Sigma methodology also entails improving processes to deliver consistent goal achievement in accordance with company strategy and consistent with customer demand. The analysis process of this Six Sigma methodology sets the stage for midway course correction, called improvement.

DMADV

This 6 sigma methodology applies to the creation of new processes for product development. This Six Sigma implementation differs from the DMAIC methodology at the final two stages. Defining and measuring the design and product goals and capabilities are the first two stages. The next stage is analyzing alternatives and evaluating to choose the best product design. The next stage consists of implementing the best design. The final stage entails verifying the design, pilot (or test) runs and testing implementation before the final presentation.

Several organizations such as Motorola, (which is a pioneer of Six Sigma), Microsoft, GE and the United States Navy have successfully implemented Six Sigma and reaped huge dividends. Six Sigma has benefited corporations with multiple products across various business sectors. Healthcare, banking and insurance, telecommunications, software, and construction are just some of the industries successfully implementing Six Sigma.

Six Sigma implementation requires organizations to play five key roles at various levels. At the top is executive leadership which includes the CEO, champions, master black belts, and black belts. Then there are the green belts, which dedicate 100% of their efforts towards the concerted implementation of the program until the end of the project. The difference between the green belts and the rest of the team is that the employees in the green belt level share the additional responsibility for Six Sigma implementation along with their normal work responsibilities.

Criticisms Of Six Sigma

Despite its scientific approach towards quality improvement, there are criticisms against Six Sigma. The most vocal one is the viewpoint that there is nothing new about Six Sigma as it imitates already existing and proven techniques. To a certain extent, this argument has some credibility. But proponents of Six Sigma believe that as long as 6 sigma achieves more predictable results with far lower effort, there is no harm in accepting and implementing it. Criticisms notwithstanding, what Six Sigma does is apply concerted efforts at utilizing existing techniques with new approaches.

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

Six Sigma Project Management

Employing Six Sigma for the business environment is for achieving well-defined goals. The project selected for deploying Six Sigma is not self-sustaining and can develop tendencies to get off target following even the slightest let up in its management. The focus of the Six Sigma management committee is to steer the project implementation to meet those stated goals within budget and time constraints.

Six Sigma Project Management Stages

Project management in Six Sigma begins even before selecting a project. In the run up to the implementation, the right kinds of people, who have proven track records, are selected for Black Belt positions. Since Black Belts are the pillars of managing six sigma, it essential that candidates have proven qualities such as attention to detail, tendency toward problem solving and a proclivity for dedicated work.

Organizational clearances, essential for project implementation, have to be sorted out at this stage. Project selection that has a potential for a high payoff cannot be missed out on any account. For example, because of lack of funds or because of organizational stumbling blocks.

Defining Project Goals And ROI

Defining project goals and estimating pragmatic ROI is essential at this stage to set the course for project implementation and for bringing it back to course if an audit shows that deviations occurred during the implementation. This is really important - if deviations are missed it will produce endless financial and customer base losses to the company. Another key aspect is setting practical ROI targets without getting carried away. The bar shouldn’t be set too high and certainly what has not evolved from the “Voice of the Customer”.

Getting Down To Measurements

Measurements are the watchdogs of a project and demand total integrity. This is the area where Master Black Belts and Champions need to concentrate completely. Black Belts can encounter undesirable pressures for misrepresenting facts, which would otherwise expose a few poor performances.

Another issue that needs to be tackled is of a more serious nature. The consultant teams have their interests in keeping the project going on for as long as possible. This fact may be seen in the fact that Black Belts employed at the company do not measure up to the reputation of the consulting firm. From this point of view, it becomes important to double check and get back to the basics to negotiate the names of professionals who are going to be deployed.

Six Sigma Audit By Internal Committee

The internal audit committee must not the audit exercise lightly, as there is much at stake. The audit committee, besides inspecting process records and documented measurements, must place a lot of emphasis on interviewing the internal customers. The interviews should focus on finding the status of efforts at minimizing customer complaints. This is clearly an exercise of contrasting the condition ‘as is’ against ‘should be’, which is the goal. The Champion will then take over the matter for brainstorming with the Master Black Belts and Black Belts. The agenda of the brainstorming session should not deviate from discussing the findings of the audit committee.

Tony Jacowski is a quality analyst for The MBA Journal. Aveta Solutions – 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.