6-SIGMA A LEAP TOWARDS QUALITY & PERFECTION

A LEAP TOWARDS QUALITY & PERFECTION

Abstract

6-sigma is a quality management program, which is not limited to any specific field. It covers all types of industries, which strive for achieving highest quality in their products. It was developed at Motorola in early 1980s. It achieves quality by reducing no. of defects in the total quantity of manufactured product.

Its basic structure is formed of 6 layers. Each layer signifies the maximum no. of defects that could be allowed per million parts of a product. As we step up through the layers, defect rate starts reducing. At the highest level, we can achieve the defect rate which is as small as 3.4.parts per million.

Achieving a sigma standard up to 6^th level is not an easy job. It requires perfection at each & every step of production. This takes care of quality even in the smallest part of production system and helps in achieving a world-class quality product.

Introduction to 6-sigma

6-Sigma is a structured, data driven methodology that can be applied to any aspect of business. It is used to improve customer satisfaction, eliminate waste and increase profit. It is a quality management program, which covers the minute things for achieving better quality.

The initial development of 6-Sigma strategies were contrived at Motorola in the early 1980’s. It was initiated because the company authorities found that some areas of their products were losing in competitiveness and costs. Later they found out that it was because of poor quality, which were only at 3 or 4 sigma levels. The CEO of Motorola then started a company wide program to improve quality to make sure that a 6sigma quality level is obtained, which is essentially at 3.4ppm, which is 3.4 parts in each million parts produced. The methodology only became well known after GE’s Jack Welch made it a central focus of his business strategy in 1995.

The main thrust of 6-Sigma is the application of statistical tools in the context of a well disciplined, easy to follow methodology. It also attacks the basic reason, which is responsible for further loss or profit issues, that is decision making. Many times the decisions are based solely on intuition or experience.

6-Sigma removes the personal touch in decisions by quantifying the issues and using statistics to provide probabilities of success and failure.

To apply such strategies in one’s business, he/she needs the proper training.

The people expert in these methods are called Black Belts. The whole initiative has been broken up into projects, which are led by Green Belts.

The program is culture change, with the Black Belts and Champions as the agents of change. It requires tenacity, mental toughness and, above all, dedication to the pursuit of perfection.