Some organizations have opted to integrate their kaizen (or rapid continual improvement) processes with Six Sigma approaches. Process performance results are again periodically monitored to ensure productivity improvements are sustained. Control. This phase involves institutionalization of the improved system by modifying policies, procedures, and other management systems. Statistical methods are again used to assess improvement. Often, other lean methods such as cellular manufacturing, 5S, mistake-proofing, and total productive maintenance are identified as potential solutions. Improve. Here, implementation of creative solutions - ways to do things better, cheaper, and/or faster - that address the problems identified during the analysis phase takes place.Analyze. This phase is concerned with identifying the root cause(s) of quality problems, and confirming those causes using appropriate statistical tools.Metrics are established and used to obtain baseline data on process performance and to help identify problem areas. Measure. In this phase, the aim is to gather information about the targeted process.Define. This phase focuses on defining the project improvement activity goals and identifying the issues that need to be addressed to achieve a higher sigma level.Method and Implementation ApproachĪ sequence of steps called the Six Sigma DMAIC (Define, Measure, Analyze, Improve, and Control) is typically used to guide implementation of Six Sigma statistical tools and to identify process wastes and weaknesses. The statistical tools of Six Sigma system are designed to help an organization correctly diagnose the root causes of performance gaps and variability, and apply the most appropriate tools and solutions in addressing those gaps. Six Sigma has evolved among some companies to include methods for implementing and maintaining performance of process improvements. It is important to note that not all companies using Six Sigma methods are implementing lean manufacturing systems or using other lean methods. A Six Sigma quality level equates to approximately 3.4 defects per million opportunities, representing high quality and minimal process variability. A sigma quality level serves as an indicator of how often defects are likely to occur in processes, parts, or products. The term sigma is a Greek alphabet letter (σ) used to describe variability. Six Sigma was developed by Motorola in the 1990s, drawing on well-established statistical quality control techniques and data analysis methods. Six Sigma is also being used to further drive productivity and quality improvements in lean operations. Six Sigma's toolbox of statistical process control and analytical techniques are being used by some companies to assess process quality and waste areas to which other lean methods can be applied as solutions. Six Sigma consists of a set of statistical methods for systemically analyzing processes to reduce process variation, which are sometimes used to support and guide organizational continual improvement activities. Implications for Environmental Performance.
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