6 Sigma

How many times have you had the situation where you have the process all set up and running fine only for it to drift out of control. You either start making parts the wrong size or with more defects or your system goes all to bits. This is process variation and it's one of the major reasons companies struggle to achieve this and it's what 6 Sigma is all about.
The process is based on 5 stages that you need to work through carefully picking up the right statistical tools as you go.
The 5 stages are: Define > Measure > Analyse, Improve and Control
The 6 Sigma methodology is about reducing, and in some cases eliminating certain types, of variation within the process to bring it under control and so reduce the number of undesired outcomes (defects) from the systems. 6Sigma works with the DMAIC process (Define, Measure, Analyse, Improve, Control) and statistical methods to identify and reduce the causes of variation within the system typically grouped into one of 4 types:
  • Off-Target variation occurs when the process average is not equal to its target value.
  • Common-Cause variation is the variation exhibited by the process while operating in its best manner.
  • Special-Cause variation results from the intervention of causes that are unplanned and undesirable.
  • Structural variation is variation inherent in the system but appears to be due to special causes on a control chart.   However, the causes of Structural variation are predictable.
It's amazing that around 95% of all issues can be addressed with as little as 7 Quality Control Tools commonly used in the 6 sigma program. These 7 tools really form the foundation of the entire 6 sigma methodology so it's important for people to know them and be able to use them effectively.

The 7 tools are:
  1. Cause & Effect Diagram, also known as a fishbone diagram 
  2. Pareto Charts
  3. Control Charts
  4. Scatter Diagrams
  5. Histograms
  6. Flow Charts
  7. Checklists

You have probably heard of them, perhaps even used a few of them, we want to help you use them all and see how they work together to effectively solve problems and control processes.
There are, of course, more than just 7 tools. Thinks like a SIPOC Analysis (Suppliers Inputs, Process, Outputs, Customers) can dramatically improve your thinking when it comes to understanding the customer's voice. Capability analysis of a machine or process capability or it's ability to repeatably produce the same thing within a specification and so many more.
We can team you as many of the tools that you need but the reality is you probably need fewer tools than you think to make a major impact on your organisation, you just need to know how, and when, to apply them and that's where Many Caps Consulting can help.

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