1. Introduction to
Presented by:
Ayush Shakya
Neeti Kumar
Rashmikat Jha
BFT- V (2011-15)

2. What is Six Sigma?
 3.4 defects per million opportunities
 Philosophy that changes the way of thinking within a
company
 Business strategy that brings a company to
competitive edge
 Business Improvement Methodology
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3. What does Six Sigma mean
practically?
 Defect reduction
 Yield improvement
 Improved customer satisfaction
 Higher net income
 Continual improvement
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4. Six Sigma Evolution
 Carl Frederick Gauss ( 1777-1855) introduced the concept of
the normal curve
 As a measurement standard in 1920’s, Walter Shewhart
showed three sigma is the point from the mean where a
process requires correction
 1970’s: Mikel Harry, a senior staff engineer at Motorola’s
Government Electronics Group began to formulate a method
for applying six sigma throughout Motorola
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5. History of Six Sigma: Motorola
 In 1987 when Bob Galvin was the Chairman , Six Sigma was
started as a methodology in Motorola.
 Bill smith , an engineer, and Mikel Harry together devised a
6 step methodology with the focus on defect reduction and
improvement in yield through statistics
 The term “Six Sigma” was coined by Bill Smith, who is now
called Father of Six Sigma
 The company saved $ 16 billion in 10 years.
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6. History of Six Sigma
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7. Six Sigma
 Performing at sigma level of six means that difference
between mean and specific limit is six times the
standard deviation.
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8. The Normal Distribution
 Generated as a result of a process experiencing random
variation
 Characterized by mean and standard deviation
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9. Measuring variation using standard deviation
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10. Objective of Six Sigma
Sigma Level
DPMO
2
308,537
3
66,807
4
6,210
5
233
6
3.4
99.99966% good- sigma level of 6
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11. Characteristics of Six Sigma
 Customer-centered
 Process-focused
 Data Driven
 Big Performance Gains
 Structured improvement deployment
 Validation through key business results, ( financial
gains in most cases)
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12. What is Six Sigma Performance?
99% Good (3.8s)
99.99966% Good (6s)
• 5,000 incorrect
• 1.7 incorrect
operations per week
operations per week
• Two short or long
• One short or long
landings at most major
landing every five
airports each day
years
• 200,000 wrong drug
• 68 wrong
prescriptions each year
prescriptions per year.
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13. Six Sigma : The Projects
•
Projects are linked to the Strategic Plan
•
Projects prioritized based on value to the business, resources
required, and timing
– Yield improvement
– Waste reduction
– Capacity-productivity improvement
– Cycle time reduction
•
Projects are formally tracked
•
Team Leader and Management are held accountable
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14. Six Sigma Improvement Methodology
D-M-A-I-C
Define
Control
Measure
ACT
CHECK
Improve
PLAN
DO
Analyze
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15. DMAIC Steps
1. Define
2. Measure
3. Analyze
4. Improve
5. Control
• Identify projects that are measurable
• Define projects including the demands of the customer
and the content of the internal process.
• Develop team charter
• Define process map
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16. 5.0
Control
DMAIC Steps
1. Define
2. Measure
3. Analyze
4. Improve
•
Define performance standards
•
5. Control
Measure current level of quality into Sigma. It
precisely pinpoints the area causing problems
•
Identify all potential causes for such problems
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17. DMAIC Steps
1. Define
2. Measure
3. Analyze
4. Improve
5. Control
• Establish process capability
• Define performance objectives
3.0
• Identify variation sources
Analyze
• Screen potential causes
• Discover variable relationships among causes and
effects
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18. DMAIC Steps
1. Define
2. Measure
3. Analyze
4. Improve
5. Control
• Hypothesis Testing
•
Process Mapping
• Regression Analysis
•
Failure Mode & Effect Analysis
• Box Plot
•
Design of Experiments
•
Control charts
•
Quality Function Deployment
• Correlation
• Regression
(QFD)
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19. DMAIC Steps
1. Define
2. Measure
3. Analyze
4. Improve
5. Control
• Establish operating tolerances
• Pursue a method to resolve and ultimately eliminate
problems. It is also a phase to explore the solution
how to change, fix and modify the process.
• Carryout a trial run for a planned period of time to
ensure the revisions and improvements implemented
in the process result in achieving the targeted values.
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20. DMAIC Steps
1. Define
2. Measure
3. Analyze
4. Improve
5. Control
• Monitor the improved process continuously to ensure
long term sustainability of the new developments.
• Share the lessons learnt
• Document the results and accomplishments of all the
improvement activities for future reference.
Control Charts:
Assigning clear process ownership and documenting
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21. Flowchart of DMAIC process
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22. Key Terms
Y’s
• Key process output variable
• Thought of in terms of performance/defect measures
X’s
• Key process input variable
• Are a list of variables that influence the response(s)
or Y’s
• Y is a function of the X’s or
Y = f(X1, X2, …)
The goal of six sigma is to understand the X’s that control the Y’s.
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23. Y = f(X1, X2, …)
Suppliers
Inputs
x
x
Outputs
Customers
x
Process
X’s, Inputs
•Process variables
•Inputs to the process
•Essential actions to
achieve strategic goals
•Key influences on
customer satisfaction
Y’s, Outputs
•Customer requirements
•Yield, Waste, Rate
•On Time Delivery
•Economic Profit
•Strategic goal
•Customer satisfaction
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24. Sigma level calculation
DPMO = DPU * 1,000,000 / OFE
• DPMO – Defects per million opportunities
• DPU – defects per unit
= No. of defects / No. of pieces inspected
• OFE – Opportunities for error per unit
= No. of characteristics inspected per unit
Sigma level = Value of Zst from the Sigma level and
DPMO table
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25. Introduction to Six Sigma
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26. Introduction to Six Sigma
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27. THANK YOU
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