Six Sigma differs from Lean in that it requires additional training for mastery of its process and an organized team capable of solving problems collaboratively.
Six Sigma is an analytical methodology focused on eliminating errors and improving processes through its DMAIC approach - Define, Measure, Analyze, Improve and Control.
Lean is a methodology
Six Sigma is an established management approach that can help companies enhance workflow and bottom line results. Its tools and techniques focus on eliminating wasteful processes, shortening cycle times and providing better products to customers; its methods draw upon Toyota Production System principles as well as DMAIC phases/methodology.
Poka-Yoke refers to a process designed to eliminate errors by mistake-proofing its steps or installing reliable alarm systems that notify them whenever a defect-causing factor appears, and is an integral component of Lean Six Sigma. To prevent errors from reoccurring by eliminating unnecessary steps or creating alarm systems that alert when something goes amiss.
Fishbone Diagrams are visual depictions of all possible causes for a problem and used to quickly pinpoint its root cause. A PDCA cycle, an iterative problem-solving technique incorporating Plan, Do, Check and Act principles. A Lower Specification Limit defines an acceptable threshold below which no process should operate while Medians represent clustered data values; also called Means.
Six Sigma is a methodology
Six Sigma is a data-driven management process used to streamline business processes. The methodology's distinctive elements are its strong customer focus and use of statistical tools for efficiency gains. Six Sigma also entails five phases: Define, Measure, Analyze, Improve and Control.
The Define stage involves gathering metrics relevant to a process under study. As part of DMAIC process, this first phase identifies and collects key measures pertaining to that particular process under scrutiny and sets forth steps necessary for reaching process improvement goals - this may involve determining what its intended look like as well as pinpointing root causes of variations, defects, or failures in its operation.
Manufacturers with six sigma certification benefit from improved visibility across their production cycle, leading to decreased emergency responses due to major product damage, mishandled materials and production halts. They will also save on overhead and direct costs while improving their bottom line. But success with six Sigma requires significant cultural changes within an organization and requires expert team of statistics and data analytics experts who work alongside Six Sigma certification.
Six Sigma is a set of tools
Six Sigma is a quality management technique that employs various tools to improve business processes. This iterative process seeks measurable financial returns while eliminating redundant steps from manufacturing and decreasing waste and error rates.
Six Sigma begins by identifying a problem, using either a value-stream map, timeline or information flow diagram (commonly referred to as fishbone diagram). Once identified, brainstorm possible causes and develop potential solutions, followed by testing and implementation; finally monitoring improvements using a control chart is performed as part of this process.
Six Sigma provides many benefits; however, its usage has also drawn some criticism. Quality expert Joseph M. Juran even expressed concerns that Six Sigma was just old wine in new bottles. But regardless of its critics' claims, Six Sigma has proven effective at improving productivity; its methodologies enable companies to strike a balance between output and overhead costs while decreasing lead times and cost-benefit ratios.
Six Sigma is a set of philosophies
Six Sigma can be defined as a set of philosophies that focus on improving the quality of products or services, using tools and techniques to remove defects in manufacturing. Six Sigma also employs an ongoing improvement approach derived from Frederick Winslow Taylor's Principles of Scientific Management as well as Walter Shewhart, W. Edward Deming, and others' work.
Certified Six Sigma manufacturers also possess greater insight into their production cycles, enabling them to execute more accurate calculations of their process' financial return. By engaging in input experimentation and using input experimentation as a framework for reducing overhead expenses and growing their bottom line.
One of the primary focuses of Six Sigma philosophy is customer satisfaction. Six Sigma teams systematically identify and assess customer needs during the Define phase of DMAIC methodology and continually monitor and measure it during each project's lifecycle; this process is known as Design for Six Sigma (DFSS). DFSS involves creating new processes, products or services tailored specifically towards fulfilling customer requirements.