Six Sigma methodology: The roadmap to operational success.
Six Sigma is a way of managing that aims to focus on making sure that problems with products, services, and processes are kept to a minimum. This method is well-organized and helps businesses reach their strategic goals by improving the quality of their processes and goods. It is used in both the industry and service sectors, and every year thousands of projects are carried out that utilize the same approach.
The Six Sigma method is used in manufacturing and process industries to achieve zero defects and increase consistency. To do this, it uses a five-step process called DMAIC, which consists of establishing opportunities, measuring performance, analyzing opportunities, improving performance, and managing performance.
Six-Sigma DMAIC methodology in Rubber manufacturing companies can reduce the defects in the production and hence, improve quality.
The Six-Sigma DMAIC methodology is divided into the following five basic phases:
- Define
In this phase, we figure out the project’s problem and its goal. There are 3 main steps in this phase: –
- Identifying the problem
- Defining the project’s goals
- Defining the customer’s needs.
- Measure
In the measure phase, 2 main steps are used to look at the current state of the problem:
- Process mapping
- Data collection.
These steps aim to find out how well the process is working right now by carefully mapping out the steps and collecting data that can be used for analysis.
- Analyse
In this phase, the data collected is analyzed using cause-effect diagram analysis to identify the major defects and their causes for addressing them to improve the process.
- Improve
This phase aims at achieving the defined goal by addressing the dominant possible causes to enhance the process. This is done by successfully handling the root causes, so that the process can work better, leading to more efficiency and progress.
- Control
The goal of the control phase is to make sure that the new and better system lasts. Thus, it needs to be strong, so that the process stays under control. In order to avoid the slow comeback of old ways that would hamper productivity and efficiency, two most important things done in this phase are:
- Ensuring workers get regular updated training.
- Identify and replace existing documents with revised ones.
The Six Sigma method has been used in many different industries worldwide, showing how flexible and useful it is for improving processes and cutting costs. Despite the challenges companies face in implementing Six Sigma due to the complexity of its phases and resource requirements, it benefits in improving market share, cycle times, customer satisfaction, and productivity.
Six Sigma has always produced big results, like a noticeable drop in the number of rejected products and general cost savings in production processes.
By combining Six Sigma with lean thought and standard quality management theory, industries can run their factories more efficiently, lower the costs of poor quality, and boost output, all of which will lead to better overall performance.