1. Six Sigma (What is it?)
“Six sigma was simply a TQM process that uses process capabilities analysis as a way of measuring progress”
--H.J. Harrington, “Six Sigma’s Long-Term Impact,” Quality Digest, June 2001
Six Sigma is a disciplined, data-driven approach and methodology for eliminating defects (driving towards six standard deviations between the mean and the nearest specification limit) in any process -- from manufacturing to transactional and from product to service.

2. Six Sigma (What can we expect?)
To achieve Six Sigma, a process must not produce more than 3.4 defects per million opportunities.

3. Nonconforming Rate When Process is Centered
Spec.
Limit
Conformance
Non-Conform. Rate (ppm) Cp
±1
68.7%
317300
0.33
±2
95.45%
48550
0.67
±3
99.73%
2700
1.00
±4 % 63
1.33
±5 %
0.57
1.67
±6 %
0.002
2.00

4. Nonconforming Rate When Process is Off-Center ±1.5
Spec.
Limit
Conformance
Non-Conform. Rate (ppm)
Cpk
±1
30.23%
697700
-0.167
±2
69.13%
308700
0.167
±3
93.32%
66810
0.500
±4 %
6210
0.834
±5 %
2330
1.167
±6 %
3.4
1.500

5. Six Sigma (What do we need to do?)
The fundamental of the Six Sigma methodology is the implementation of a measurement-based strategy that focuses on process improvement and variation reduction through the application of Six Sigma improvement projects.
DMAIC process (define, measure, analyze, improve, control) for existing processes falling below specification and looking for incremental improvement.
DMADV process (define, measure, analyze, design, verify) for developing new processes or products at Six Sigma quality levels.

6. Six Sigma (DMAIC) For existing process
Define the project goals and customer (internal and external) deliverables
Measure the process to determine current performance
Analyze and determine the root cause(s) of the defects
Improve the process by eliminating defects
Control future process performance

7. Six Sigma (DMADV) For product/process development
Define the project goals and customer (internal and external) deliverables
Measure and determine customer needs and specifications
Analyze the process options to meet the customer needs
Design (detailed) the process to meet the customer needs
Verify the design performance and ability to meet customer needs

8. Six Sigma (What do you need to know?)
Define
Project Definition / Management
Developing a Business Case
Chartering a Team
Defining Roles and Responsibilities
Gathering Voice of the Customer, Support for Project
Translating Customer Needs into Specific Requirements
SIPOC (Suppliers, Inputs, Process, Outputs, Customers) Diagram

9. Six Sigma (What do you need to know?)
Measure (1)
Process Mapping (As-Is Process)
Data Attributes (Continuous Versus Discrete)
Defining Metrics
Measurement System Analysis
Gage Repeatability and Reproducibility
Data Collection Techniques
Calculating Sample Size

10. Six Sigma (What do you need to know?)
Measure (2)
Data Collection Plan
Understanding Variation
Measuring Process Capability
Calculating Process Sigma Level
Rolled Throughput Yield
Visually Displaying Baseline Performance

11. Six Sigma (What do you need to know?)
Analyze (1)
Visually Displaying Data (Histogram, Run Chart, Pareto Chart, Scatter Diagram)
Detailed (Lower Level) Process Mapping of Critical Areas
Value-Added Analysis
Cause and Effect Analysis (a.k.a. Fishbone, Ishikawa)
Affinity Diagram
Data Segmentation and Stratification
Correlation and Regression (Linear, Multiple)

12. Six Sigma (What do you need to know?)
Analyze (2)
Process Performance (Cp, CpK, Pp, PpK, CpM)
Short Term Versus Long Term Capability
Non-Normal Data Distribution Transformations
Central Limit Theorem
Goodness of Fit Testing
Hypothesis Testing
Analysis of Variance (ANOVA), Two Sample T-Tests, Chi Squared Test

13. Six Sigma (What do you need to know?)
Analyze (3)
Design of Experiments (DOE) - Full, Fractional Factorials
Verification of Root Causes
Determining Opportunity (Defects and Financial) for Improvement
Statistical Software

14. Six Sigma (What do you need to know?)
Improve
Brainstorming
Multi-Voting
Process Simulation
Quality Function Deployment
Selecting a Solution
Failure Modes and Effects Analysis (FMEA)
Poka Yoke (Mistake Proofing New Process)
Piloting Your Solution
Implementation Planning
Culture Modification Planning

15. Six Sigma (What do you need to know?)
Control
Assessing The Results of Process Improvement
Statistical Process Control (SPC)
Rational Sub-grouping
Establishing Process Standards for Inputs, Process and Outputs
Developing a Process Control Plan
Documenting the Process
Statistical Software

16. Six Sigma (What is the benefit$$?)
According to the Six Sigma Academy, Black Belts save companies approximately $230,000 per project and can complete four to 6 projects per year.
General Electric, one of the most successful companies implementing Six Sigma, has estimated benefits on the order of $10 billion during the first five years of implementation. ( )