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Category: On Six Sigma

Jul. 14, 2012

Permalink 11:30:00 am, by admin, 80 words   English (US) latin1
Categories: On Six Sigma

Simple Sample Size Calculator

Super Simple and Easy Sample Size Calculator!

For those of you who need a quick way of calculating sample size with continuous data, we've added a new and very simple page that allows just that. All you need is your sample standard deviation and an acceptable margin of error. We take care of all rest! With only those two bits of information provided, we return sample size recommendations for 99%, 95% and 90%  confidence intervals. Check it out at the following page:

Apr. 24, 2012

Permalink 10:35:00 pm, by admin, 118 words   English (US) latin1
Categories: On Six Sigma

Affordable Six Sigma Certificaiton

We regularly receive inquiries as to Six Sigma certification and how someone might affordably attain a globally recognized certification.  Fortunately, what most people don't realize is that the two most widely achieved certifications are also the two most affordable (ASQ and IASSC).   The only point to consider is how best to prepare for such certifications.

Six Sigma Digest has prepred self study packages for both Green Belt and Black Belt certifcation preparation which align unbelievably well with both the IASSC and ASQ body of knowledge (BOK) requirements for each of their six sigma certifications.

Read more about the two most affordable six sigma certificaitons... or check out our self study courseware to begin your six sigma certificaiton preparation.

Dec. 01, 2011

Permalink 10:12:00 am, by Michael, 366 words   English (US) latin1
Categories: On Six Sigma

The Value of Six Sigma Certification

Six Sigma CertificationWhat is the value of Six Sigma certification?

Your Six Sigma certification can be priceless to you or it can be detrimental to you - the choice is yours.  Certification by itself is not a magic bean so don't assume having it on your resume will put you on top of the heap.  But, while there's no guarantee that certification will get you that special job or promotion, for some positions, certification is the price of admission into the game.  For others it's clearly a differentiator.

If you're in a field or entering a field where it’s expected then certification is a "must have".  If it's not mandatory but valued by the industry or corporation then certification is a "nice to have".    In both cases you should strongly consider getting trained and certified.  But don't stop there...

The certification alone will not inherently make you more valuable to any company.  It's YOU that makes you valuable to them.  More specifically it's what you can do with your knowledge and skills on their behalf.  If you can show on your resume that your certification helps you deliver effective results and be a successful project manager, analyst, leader, supervisor etc. then the certification takes on a whole new value proposition for you and the hiring firm.

The certification process is what introduces you to a proven methodology and a whole world of knowledge, tools and know-how.  Learn it and learn to use it effectively and your certification will be unbelievably valuable.

On the other hand if you just get certified and stick it on your resume with not further application and study then your certification will be worthless and even perhaps detrimental.  Why detrimental? because when those who value it realize you're paper certified and can't back it with results then you'll be quickly dismissed and you don't want that!

So what's the value of certification?  It’s up to you.  Should you get certified?  The Answer is certainly a yes if you can think of and treat your certification like it's the beginning of your journey and not the end.  If you do that then I can assure you that your journey will be filled with learning and growth.

Oct. 15, 2011

Permalink 10:18:00 pm, by Michael, 783 words   English (US) latin1
Categories: Project Digest, On Six Sigma


In my last article I explained that Six Sigma is simply a goal, a goal to be 99.99967% good.  Hopefully I have expressed in words (probably too many) that it's really nothing more than that, a goal.  Now, I want to share with you the process that is prescribed and necessary to follow in order to achieve this goal.  The process is referred to as D.M.A.I.C. and it's part of the Six Sigma methodology.

The Six Sigma methodology is DMAIC which is an acronym that refers to the 5 phases of a Six Sigma project.  These phases each have specific objectives that are characterized by their one word name...Define, Measure, Analyze, Improve, Control.   Each phase has a predefined set of deliverables and tools that should be used to achieve the deliverables.  If followed, the Six Sigma methodology works, I've personally lead, coached, sponsored or championed enough projects to know, the methodology does work.

So what are the deliverables and tools?  You'll get to know them quite well if you continue to follow this blog but you will truly learn them if you apply them yourself.  Here's a breakdown of each phase and the goals & tools:

Define Phase Goals

The goal of Define is to establish the projects foundation. This is arguably the most important aspect of any Six Sigma project. All successful projects start with a current state challenge or problem that can be articulated in a quantifiable manner. Additionally, it is not enough to just know the problem; you'll also determine the goal.

Once problems and goals are identified and quantified the rest of the define phase will be about valuation, team, scope, project planning, time line, stakeholders, VOC/ VOB etc.

Define Phase Tools

  • Project Charter
    • Problem Statement
    • Business Case
    • Objective
    • High level time line
    • Project Scope
    • Project Team
  • Stakeholder Assessment
  • Pareto Charts
  • VOC/VOB & CTQ's
  • High Level Process Map

Measure Phase Goals

The goal of the Measure phase is to gather baseline information about your process or product. Throughout the measure phase you will seek to achieve a few important objectives:

  • Gather All possible x's
  • Analyze your measurement system & Data Collection Requirements
  • Validate Assumptions
  • Validate Improvement Goals
  • Determine COPQ
  • Refine Process Understanding
  • Determine Process Capability
  • Process Stability

Measure Phase Tools

  • Any Appropriate Tool from Previous Phase
  • Process Maps, Value Stream Mapping
  • Failure Modes & Effects Analysis (FMEA)
  • Cause & Effect Diagram
  • XY Matrix
  • Basic Control Charts
  • Six Sigma Statistics
    • Basic Statistics
    • Descriptive Statistics
    • Normal Distributions
    • Graphical Analysis
  • Measurement Systems Analysis
    • Variable Gage R&R
    • Attribute Gage R&R
    • Gage Linearity & Accuracy
    • Gage Stability
  • Process Capability (Cpk, Ppk) & Sigma
  • Data collection plan

Analyze Phase Goals

The Analyze phase is all about establishing verified drivers. In the Six Sigma methodology, Analyze uses statistics and higher order analytics to discover the fact-based relationship between the your process performance and the x's (in other words, what are the root causes or drivers of your improvement effort). Ultimately, you must establish a hypothesis for your improvement solutions.

  • Establish Transfer Function Y=f(x)
  • Validated List of Critical X's & Impacts
  • Beta Improvement Plan (e.g. Pilot Plan)

Analyze Phase Tools

  • Any Appropriate Tool from Previous Phase
  • Hypothesis Testing
  • Simple Linear Regression
  • Multiple Regression

Improve Phase Goals

The goal of the Improve phase is guessed it! "make the improvement". Improve is about designing, testing and implementing your solution. To this point you have defined the problem and objective of the project, brainstormed possible x's, analyzed and verified critical x's and now it's time to make it real!

  • Statistically Proven Results from Active Study/Pilot
  • Improvement/Implementation Plan
  • Updated Stakeholder Assessment
  • Revised Business Case with Investment ROI
  • Risk Assessment/Updated FMEA
  • New Process Capability & Sigma

Improve Phase Tools

  • Any Appropriate Tool from Previous Phase
  • Design of Experiment (DOE)
  • Implementation Plan
  • Change Plan
  • Communication Plan

Control Phase Goals

The last of the 5 core phases of the Six Sigma methodology is the Control phase. The goal of Control is establish automated and managed mechanisms to maintain and sustain your improvement. A successful control plan also establishes a reaction & mitigation plan as well as an accountability structure.

Control Phase Tools:

  • Control Plan
  • Training Plans
  • Poka-Yoke and/or Audit Plans
  • Translation Plan - How can this be translated to others

Below is an image that captures the Six Sigma methodology and all five phases of DMAIC.  It highlights each phase, its goal and the deliverables.

six sigma methodology

Now that you have a reasonable understanding of "what is six sigma" and the Six Sigma methodology (DMAIC).  It's time for us to start following the process and begin executing our Six Sigma project.  We'll start with a project charter which will force us to define a few things and document our project.  Join me and we'll walk through the DMAIC methodology together.

Permalink 12:28:00 am, by Michael, 815 words   English (US) latin1
Categories: Project Digest, On Six Sigma

What is Sigma

There's no better place to start our Six Sigma project than to explain a bit about "what is sigma" and then more specifically what is Six Sigma.  Did you know that the global search volume for the key word "Six Sigma" is 1,000,000/month!  That’s one million people searching the term Six Sigma every month.  A fair volume of interested folks but that’s not the really interesting part, the really interesting part is that there are 11,000,000 searches for the term "what is sigma" and another million who search for the term "what is six sigma".

It's safe to say that millions of people wonder what six sigma is, maybe it's because very few people can explain it simply and do it justice at the same time.  Honestly, I struggle with it myself but I'll give it a whirl despite the fact that it's like trying to nail a cube of Jell-O to a tree!

Six Sigma is simply a goal, to perform an operation successfully 99.99967% of the time.

Imagine ONE MILLION attempts and

  • missing only 3.4 putts
  • missing only 3.4 foul shots
  • missing only 3.4 field goals

That would be exceptional...and in fact, that would be Six Sigma.  Yes, that's the craze! and companies aspire to achieve ever increasing levels of production efficiency and quality every day.  They use automation, process standards, secondary and tertiary systems and other variation reduction techniques that create instances all over the globe where Six Sigma is already achieved.  To add some perspective, it's a lofty goal but it's also achievable in many industries.

The airline industry is one such industry.  Over the past 25 years the commercial airline industry has operated at 6.61 Sigma in terms of fatal incidents.  6.61 Sigma is a fatal incident rate of 0.0000163% or 0.163 incidents per million flights.  But what if the industry only operated at a 99% success rate (about 3.83 sigma)?  That would mean over 5,200 fatal incidents per month!  Yes, you're reading that correctly, there were an average 523,466 commercial domestic flights per month for the past 25 years and at a 99% success rate, 1% or 5,235 of them would result in a fatal incident every month.    But that's not our reality.  When lives are on the line, we ensure safety measures yield adequate risk tolerances by using error proofing, automation, secondary systems and in some cases tertiary systems.  These expensive countermeasures result in a transportation method that is one of the safest available.  In turn, we have an industry that demonstrates that Six Sigma is achievable.

Now you’re probably wondering what about the "sigma" part and why six?   Well, sigma is just a term used by statisticians to refer to variation.  You'll hear this often as you follow along with me, variation is the enemy.  Take for example your favorite pair of jeans.  They are probably your favorite mostly because at some point they fit so perfectly that you fell in love with them.  But, how many times did you try on the same size jeans in the same brand and they all fit differently?  That's the variation in production processes that Six Sigma intends to eliminate.  How nice would it be to know that you could buy the same brand of jeans in the same size and get the same fit every time?  Yeah i know!

Most processes have specification limits or targets to meet.  Your jeans for example might have a waist circumference labeled 34 inches but the production process that cut them might have specification limits to stay within e.g. 33.85 - 34.15 inches.  Sigma refers to the number of standard deviations between the process average and those specification limits.  If the production process can be precise enough to cut the jeans on average at 34.01 inches with a standard deviation of 0.04 inches then it is likely that they would stay within the specification limits 99.99967% of the time or Six Sigma.  The image below depicts a process operating at 6 sigma.  Notice there is plenty of room for the process to shift around still not product defects.

On the other hand, the cut can average 34.00 on the nose with a higher or wider standard deviation which means that the cutting process may render cuts outside of the predefined specification limits ("out of spec").  Out of spec conditions are defects and we want to avoid them.  See the image below depicting a process operating at approximately 4.25 sigma.  The red "tails" of the distribution are outside of the specification limits indicating defective products.

So there you have it, the longest answer to a simple question you never wanted to hear!  and this is just the beginning :-).  Lets back up and rewind a little before we move on, please remember this...

Six Sigma is just the goal.

There is something else very important that you're going to learn on the heels of this simple but important concept.  It's that there is a proven and well-structured method you can use to achieve Six Sigma.  The method is D.M.A.I.C and we'll learn that next.

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