Getting started with Six Sigma

The purpose of this step is to objectively setting up current baselines as the basis for improvement. This is a data collection stepthe purpose of which is to establish process performance baselines. Following are the deliverable of this phase:

• Identify Solutions to overcome the impact of root causes
• Refine Solutions (FMEA, Poka-Yoke)
• Pilot Solutions
• Statistically validate results

Identify Solutions to overcome the impact of root causes

For each of the root causes identified in the Analyze phase, the Lean Six Sigma Team uses an apt structured or unstructured brainstorming method to generate various alternatives to overcome the problem. These technique may include Channeling, Analogy, Wishful thinking, Anti-solutions, Random word stimulus methods etc.

Proposed solution can be a new process, policy changes, technology change, alterations of inputs, measurement systems refinement, customer, employee or vendor education etc.

Refining the Solutions (FMEA, Poka-Yoke)

Implementing solution the Six Sigma Green Belt needs to check that the proposed solutions are well refined and complete. This will ensure that there is rework during implementation, no delays and the full impact on CTQ is derived. The main purpose of this tool is to assess all the risk involved with solutions and how to mitigate them by refining the solutions before implementations. Risk Priority Number (RPN) derived from FMEA help in prioritizing the risk and acting on them in a systematic way.

Mistake-proofing (Poka-Yoke, in Japanese) is a method used to ensure that the proposed solution doesn’t induce additional defects or errors

Pilot Solutions

The purpose of the pilot is to assess its impact in a control group setting. Based on the quantitative and qualitative results of the pilot necessary alternations solution can be incorporated to the final. Six Sigma Green Belt will closely work with the process owners during pilot to understand build ownershipand ground realities.

Statistically validate results

It is an important step to statistically validate the impact on CTQ (after implementation &before Implementation). Hypothesis tests like Chi-square tests, 2-t test, ANOVA, etc. are used to perform statistical validation. These tests identify if the improvement is marginal or significant in nature. Six Sigma Green Belt should be able to select and perform appropriate tests using statistical software’s.