One of the main concerns of manufacturing businesses is dealing with defective products due to certain issues in production. This causes a waste of resources and money loss for the owners. When manufacturers want to overcome this challenge, they adopt Six Sigma in manufacturing.
It is a method that top Fortune companies have been using to improve all types of manufacturing processes. In this blog post, we will learn about the Six Sigma meaning and how it is used in the manufacturing industry to improve product quality and profitability.
What Is Six Sigma? Definition & Meaning
The simple Six Sigma definition is a set of methods and tools that manufacturing companies use to improve manufacturing processes. An engineer named Bill Smith developed this concept when he was working at Motorola in the 1980s.
6 Sigma concept involves analyzing statistics to identify processes causing defects in the products and adopting techniques and tools to improve those processes.
The foundation of Six Sigma is the bell curve, a graph that shows how data is spread out in a process. The main parts of this graph include the mean (average) and standard deviations.
In a perfect Six Sigma process, the aim is to have 99.99966% of the data points fall within six standard deviations (sigmas) from the mean, which means only 3.4 defects per million opportunities. This high standard and features of six sigma makes sure that processes are very efficient and produce very few defects, leading to better quality and consistency in manufacturing. Understanding the bell curve helps identify variations in processes and make data-driven decisions to improve performance.
Jack Welch, from General Electric, also adopted Six Sigma in manufacturing for his company in 1995. Now, more than half of Fortune companies in the world use the concept of Six Sigma to make their manufacturing processes defect-free. The Six Sigma approach is very helpful for improving customer satisfaction and increasing profitability for SMEs.
Goals Of Six Sigma
The main goal of Six Sigma is to improve the accuracy of product specifications and the efficiency of manufacturing processes. Manufacturers aim to improve product quality and production costs simultaneously. For this, they plot the results of the manufacturing processes in a bell-shaped curve.
- If the outcomes are at the center of this curve, then the processes and product quality will be perfect as required.
- If the outcomes are more than three deviations or Sigma distances above or below the center point, then a defect in product quality and processes is identified.
Thus, the goal of Six Sigma in manufacturing is to keep everything between Six Sigma distances (three above and three below) from the center point of the bell-shaped curve. This makes sure that the products are manufactured to the required quality standards.
Lean Six Sigma Approach And Methodology
The lean Six Sigma approach and methodology is focused on combining the principles of lean manufacturing and Six Sigma. Lean manufacturing is a method that minimizes waste in production processes, while Six Sigma processes reduce variability to improve product quality.
When both methods are combined, it is known as Six Sigma lean manufacturing. This improves product quality and minimizes waste, which ultimately increases the profitability of the manufacturing businesses.
Key Processes Involved In Six Sigma
Six Sigma processes involve several steps to reduce defects and improve manufacturing efficiency. Processes can vary for different Six Sigma methods, such as DMAIC (Define, Measure, Analyze, Improve, Control) and DMADV (Define—Measure—Analyze—Design—Verify).
For example, if you are adopting DMAIC, you have to define your goals, measure your current processes, analyze your collected data, improve the required steps, and control the improved processes. On the other hand, the steps for the DMADV method, such as defining, measuring, and analyzing, are the same as those used for the DMAIC method. You must further design new processes according to your requirements and verify them to make sure they reduce defects.
Requirements For Implementing Six Sigma In Manufacturing
The implementation of Six Sigma should be according to your requirements and goals. Here are the key Six Sigma requirements for the implementation in manufacturing industries.
- Support from the top management.
- Involvement of all the departments and stakeholders.
- Training of the people involved in the manufacturing processes, whether they are executives or employees.
- Identification of the areas that cause defects in product quality.
- Data collection from all the manufacturing processes.
- Data analytics tools to analyze data for better decision-making.
- Smooth implementation of Six Sigma in manufacturing processes.
Six Sigma Rules And Principles
Six Sigma rules and principles are focused on improving customer satisfaction by providing them with high-quality products. The main Six Sigma rule is to collect data and statistics and analyze them to identify defect-causing processes. It further requires adopting techniques and tools to improve those processes.
Six Sigma DMAIC Method (Define, Measure, Analyze, Improve, Control)
The Six Sigma method/Six Sigma methodology DMAIC is widely used in manufacturing industries. This method in manufacturing involves five steps: Define, Measure, Analyze, Improve, and Control. Let’s explain them for a better understanding.
- Define: It requires you to identify the problems in your processes, understand your customer demands, and define your manufacturing goals.
- Measure: This step requires you to collect all the data from current processes and measure their performances.
- Analyze: In this step, you analyze all the collected data, find the root cause of problems, and determine the techniques and tools that can solve your issues according to your requirements.
- Improve: In this step, you implement your selected techniques and tools on pilot projects to test their efficacy. If they fulfill your requirements, you adopt them in your manufacturing industry to increase accuracy and profitability.
- Control: This process requires you to control your processes to prevent defects in the future and improve continuously.
Lean Six Sigma Integration
Lean Six Sigma integration means combining Lean’s methodology and Six Sigma principles. Lean methodology is focused on reducing any kind of waste, such as overproduction, overstocking of raw materials, inefficient use of resources, bottlenecks causing downtime, etc.
On the other hand, Six Sigma in manufacturing processes makes sure that products are manufactured according to specified quality standards. It involves data analysis, statistical approaches, process improvement, etc.
It results in reduced waste and manufacturing lead time and improved product quality, which shows the importance of Six Sigma and lean methodology integration.
Lean Six Sigma In Operations Management
Lean Six Sigma in operations management is the optimization of processes according to your specific requirements and goals. It allows you to remove waste and variability simultaneously. It requires you to use tools like statistical process control, process mapping, and control charts. It helps you identify bottlenecks and opportunities to improve your planning and production processes. It also helps you increase production rates to achieve production targets with improved product quality and reduced waste.
Lean Six Sigma Certification
Lean Six Sigma certification can be different and similar to the martial arts belt systems. It depends on your preparation and training whether you are eligible for a white, yellow, green, or black belt.
If you are a beginner and know the basics of Lean Six Sigma in manufacturing, then you can get a white belt. If you have completed courses for your specific requirements, then you can get a yellow belt.
If you have gone through advanced training and preparation, then you can be eligible for a green belt. If you have become the master of Lean Six Sigma in manufacturing, then you can get a black belt.
The top Fortune 6 Sigma companies like Motorola and General Electric have black belts and are the leaders of the manufacturing industries.
Application Of Six Sigma In Manufacturing
The application of Six Sigma in manufacturing industries is very efficient in reducing downtime and improving product quality. Total Quality Management (TQM) and Continuous Quality Improvement (CQI) are the effective techniques for Six Sigma applications that manufacturers have adopted since the 1980s and 1990s.
You can use tools like Measuring System Analysis (MSA) to improve accuracy in your manufacturing processes. Since Six Sigma management depends largely on data analysis, you can use other tools like Quality Function Deployment (QFD), Design of Experiments (DOE), and Failure Mode & Effect Analysis (FMEA).
Additionally, Lean Six Sigma application examples include using tools like inventory management systems, material resource planning software, and master scheduling software to prevent waste and improve manufacturing processes. All these applications of Six Sigma in production in manufacturing industries help reduce variability and defects and improve product quality.
Examples Of Six Sigma In Manufacturing
Six Sigma in manufacturing can be applied to each process, whether it is demand forecasting, production planning, or quality control. Let’s learn about this in detail with a few Six Sigma examples based on different operational processes.
1. Six Sigma In Operations Management
Six Sigma in operations management is the improvement of processes through the collection and analysis of data. You can use data analysis tools and techniques like Failure Mode and Effect Analysis (FMEA) and Regression Analysis to improve your operations. It can help you identify issues that cause defects and waste so that you can improve quality and operational efficiency.
2. Six Sigma In Production Management
Six Sigma in production management is focused on the production processes. It requires you to collect and analyze production data and identify bottlenecks. You can implement Standard Operating Procedures (SOPs) and Control charts to reduce downtime and defects in the production processes. For this, you can set guidelines according to your unique requirements and train your employees to maintain product quality and improve production efficiency.
3. Six Sigma In Supply Chain Management
Six Sigma in supply chain management is focused on improving processes like procurement and inventory management. It requires you to improve communication and collaboration between departments and suppliers. You should also have a good relationship with alternative suppliers to avoid disruption in the supply chain. Accurate demand forecasting and material requirements planning can also improve your supply chain management.
Benefits Of Implementing Six Sigma
Implementing Six Sigma in manufacturing provides numerous benefits. Here are the key benefits of implementing Six Sigma in manufacturing.
- Data-driven decisions.
- Reduced downtime and waste of resources.
- Nearly defect-free processes.
- Products with the required quality standards.
- Increased operational efficiency.
- Better order management.
- Improved customer satisfaction.
- Higher return on investments (ROIs).
Challenges In Implementing Six Sigma
Here are some challenges that you may face when implementing Six Sigma in manufacturing.
- Data collection from all your manufacturing processes.
- Cost of implementation of software solutions.
- Integrating Six Sigma with your current processes and systems.
- Potential downtime while implementing Six Sigma.
- Preparation and training of your employees.
Tools And Software For Six Sigma
Many six sigma software and tools are available that can help you reduce defects. You need to analyze your specific requirements to get the best Six Sigma tools and software for maximum benefits.
For example, if you are facing problems with inventory adjustments, then you can adopt inventory management software. Similarly, if your production processes are causing you downtime and defects, then you can implement production planning software or master scheduling software. For advanced planning and data analysis, you can use tools like Histograms, Pareto Charts, and value stream mapping.
Final Thoughts On The Role Of Six Sigma In Shaping The Future Of Manufacturing
The role of Six Sigma in shaping the future of manufacturing is very important. With advanced data analysis and process improvement, it allows you to manufacture products in large quantities with nearly zero defects. For this, you just need to implement the right software in your manufacturing industry.
TranZact can help you collect the required data for Six Sigma implementation. It helps you reduce waste with better inventory management solution and avoid disruptions in the supply chain.
It also helps you monitor processes with 6 Sigma quality control features. Additionally, it doesn’t need a higher investment in training your employees as it requires basic skills to operate.
Choose TranZact today to simplify your manufacturing operations, starting from enquiry to dispatch.
FAQs
1. What is Six Sigma and how does it apply to manufacturing?
Six Sigma is a set of methods to reduce defects and improve product quality. It applies various tools and techniques in manufacturing to improve processes and efficiency.
2. What are the key principles of Six Sigma?
The key principles of Six Sigma are collecting and analyzing data from all manufacturing processes, identifying defect-causing steps, and implementing tools and techniques for improvement.
3. Can Six Sigma be integrated with Lean Manufacturing principles?
Yes, Six Sigma can be integrated with lean manufacturing principles to reduce waste of resources and defects and improve efficiency and product quality.
4. What are some examples of successful Six Sigma applications in manufacturing?
The identification of bottlenecks in production processes, reduction in product defects, and efficient supply chain are some examples of successful Six Sigma applications in manufacturing.
5. What tools and software are used in Six Sigma for manufacturing?
The tools and software used in Six Sigma for manufacturing are as follows:
- Inventory Management Software
- Histograms
- Pareto Charts
- Value Stream Mapping
- Regression Analysis
6. How can individuals get certified in Six Sigma and what are the career benefits?
Individuals can get certifications like a white, yellow, green, and black belt from organizations like the American Society for Quality (ASQ) and Chartered Quality Institute (CQI). The career benefits include improved skills and higher ROIs.
7. What are the benefits of implementing Six Sigma in manufacturing?
The benefits of implementing Six Sigma in manufacturing are:
- Reduced Product Defects
- Better Quality Control
- Optimized Manufacturing Processes
- Data-Driven Decisions
- Increased Profitability
8. How does Six Sigma differ from traditional quality management approaches?
Six Sigma differs from traditional quality management approaches as it provides higher data-driven and systematic processes.
