Six Sigma was developed by Motorola Inc in 1986. Objective behind developing the tool was to make the manufacturing processes efficient.

First Phase – Define:

Here, problem/s are defined. This is the key phase in the process. The quality and customer needs are understood. Then the project scoping is done.

Second Phase – Measure:

This is a crucial phase. The Measure Process Performance is a crucial step in six sigma.

Tools like a Pareto chart is used to see the frequency of the problem and its impact. The present capability of the system must be assessed to check whether it meets the desired goals.   

Third Phase – Analyze:

Analysis of the problem leads to the identification of the cause. In this stage, tools like Root Cause Analysis (RCA), Failure Modes and Effect Analysis (FMEA), and Multivariate Charts are used.    

Root cause analysis is used to detect the main cause of the defect. FEMA is used in identifying failure rates of products and services.    

Multivariate charts enable an assessment of different types of variations within a process. It shows most of the variations.  It also breaks down the deviations to its components.

Fourth Phase – Improve:

In this phase, Improvement actions are initiated after carrying out the Root Cause Analysis. Design of Experiments (DOE) is used when there are complex problems. In such a case, many factors influence the outcome, and it is difficult to single out them. DOE helps in this.    

Kaizen Events help in focusing on rapid transition. It narrows down the project and maintains focus.    Kaizen or DOE are used in conjunction while implementing Six Sigma.

Fifth Phase – Control:

Control is exercised with techniques like QCP, SPC and 5S. Quality Control Plan (QCP) enables managers to decide the actions are needed to be taken to ensure process improvement.    

Statistical Process Control (SPC) empowers the management to monitor processes across the departments.    

5S is adopted for reducing waste and inefficiency. It enables the maintenance of the workplace with visual controls.  

There are many examples of effective implementation of six sigma in corporates.

Airbus:

This company could reduce the cycle time for repair, maintenance and overhauling activities of their aircraft by applying Six Sigma.
 
The cycle time of Airbus was reduced by 21 percent by visual management and in-house software.

The company could gain USD 7,07,000 per year.

Cost-benefit and root cause analysis where the focus area in the company to implement Six Sigma.

Ford Motor Company: 

This company could determine successfully the root cause for defects.  

They successfully transitioned from petroleum-based foam to castor oil foam which is more environment friendly.

Earlier the company had a scrap rate of 30 percent.

This got reduced to 0.1 percent as a result of the implementation of the Six Sigma process.

Sigma is applied in diverse industries.

Its wide application is adopted in India too.