What is Six Sigma?

Six Sigma is a data-driven and structured improvement approach used to create more stable processes, reduce variation and improve the quality of operations. The method is based on the entire organization, from operational level to management, working together to identify causes of errors and work towards clear, measurable goals.

The concept was developed by Motorola in the 1980s and is now used globally in industry, manufacturing, services and IT. The aim of Six Sigma is to identify the causes of problems and optimize processes so that the result is as close to perfection as possible.

Benefits of Six Sigma

• Reduces variation and errors in processes
• Improves quality and customer satisfaction
• Streamlines resource utilization
• Creates data-driven decision making
• Builds a culture of continuous improvement

Six Sigma as a method

Six Sigma is a systematic improvement process that involves the entire organization. It is usually implemented through one of two established models: DMAIC, which focuses on improving existing processes, or DMADV (DFSS - Design for Six Sigma), which is used in the development of new products and processes where quality needs to be built in from the start.

DMAIC

1. Define - Define and describe the problem, goal and scope of the project. Identify the customer and what creates value.
2. Measure - Collect facts and data to understand the current situation and quantify the scope of the problem.
3. Analyze - Identify root causes of variation or errors using statistical analysis and process mapping.
4. Improve - Develop, test and implement solutions that address the root causes.
5. Control - Ensure that improvements are maintained through standardization, follow-up and monitoring over time.

DMADV (DFSS)

1. Define - Clarify customer requirements, project objectives and business needs.
2. Measure - Map customer needs and define critical quality parameters (CTQ).
3. Analyze - Explore and compare different solution options that can meet customer needs.
4. Design - Design the new process or product based on analysis and simulated performance.
5. Verify - Test and verify that the solution works in practice and meets all requirements before full-scale implementation.

8D - common ground in problem solving

Six Sigma and 8D have a lot in common: they are based on structured, data-driven approaches to solving problems and improving quality. The 8D approach is often used for non-conformances and complaints, while Six Sigma focuses on measuring and eliminating variation in processes. By combining these methods, organizations can both address immediate problems and work on long-term process improvements.

5S - order and stability

To fully succeed with Six Sigma, organization is required. This is where the 5S method comes in - a Lean principle that creates order, structure and standardized ways of working. By sorting, systematizing and creating self-discipline, the business gets a stable foundation where deviations are detected faster and improvements are easier to implement.

Lean - focus on flow and value creation

Six Sigma can be advantageously combined with Lean to create the conditions for stable, efficient and customer-oriented processes. Lean focuses on flow, value creation and reducing waste, while Six Sigma focuses on reducing variation, improving accuracy and making data-driven decisions.

Six Sigma training and roles

To work effectively with Six Sigma, a clear competency structure, inspired by martial arts belt levels, is used. It provides the organization with a common understanding of roles, responsibilities, and expected knowledge levels in the improvement effort:

• White Belt: Has basic knowledge of Six Sigma and is often involved in supporting simple improvement activities.
• Yellow Belt: Participates in improvement projects, contributes to data collection and understands the basics of DMAIC.
• Green Belt: Leads smaller projects and analysis alongside their regular role. Has a good understanding of tools and data analysis.
• Black Belt: Leads major improvement projects, trains others and uses advanced statistical methods.
• Master Black Belt: Strategic expert who coaches the whole organization, develops Six Sigma training and ensures the methodology is applied correctly.

How to succeed with Six Sigma

Successful Six Sigma implementation requires structure, commitment and the right tools. It works best when the organization combines data-driven analysis with active improvement efforts on a day-to-day basis - preferably in conjunction with other methods such as Kaizen or TQM (Total Quality Management).

Here are 8 concrete tips for success:

1. Ensure management support: Effective Six Sigma initiatives require clear goals, resources and mandates from management.
2. Build cross-functional teams: Involve employees from different functions to get a broader picture of problems and root causes.
3. Work consistently with data: Base decisions on facts, not assumptions - data quality determines the outcome.
4. Standardize improvements: New ways of working need to be documented and embedded so that they become part of everyday life.
5. Invest in Six Sigma training: Ensure the right skills by developing internal Yellow, Green and Black Belts.
6. Start small and scale up: Test the method in a limited area, evaluate and then grow.
7. Link the approach to business objectives: Choose projects that clearly impact quality, costs or customer value to have maximum impact.
8. Encourage a culture of improvement: Work continuously with ideas, workshops and Kaizen-inspired activities to keep the commitment alive.