If there was a small word that describes how Six Sigma training for quality control works, it might be the word “same.” This highly focused training brings everyone to the same point. Everyone gets the same message, and everyone is looking for the same thing, at the same time. The result is improved quality control because all employees and managers are on the same page, focused on the same task of achieving excellence.
The program itself is very different from other programs. This is a type of business management strategy that was first developed and implemented by Motorola. The applications for use of Six Sigma training for quality control are widespread in many areas of industry.
The Goal of Six Sigma Training
The basic goal of Six Sigma training for quality control is to reduce defects and errors at every step along the way. Whether this applies to production or service does not matter; the goal of excellence and zero defects is the same. With everyone seeking perfection, and more importantly, looking for errors at every step, it is possible to bring down any defect or error rate to near or at zero.
One difference in the Six Sigma training program structure is the use of statistical methods to measure and assess the results. In order to do this, Six Sigma utilizes an infrastructure of personnel working within a business or organization. Each has a particular role to play and steps to follow. Each has a defined goal, such as cost reduction or increasing profit numbers. To differentiate and make clear the duties of each person involved in the Six Sigma training program, each person is designated as having a different status.
The levels within Six Sigma training are patterned after levels of performance and achievement found in the martial arts programs of Karate. There are different “Belts” awarded to personnel, based on their role in the entire program. There are Champions, Master Black Belts, Black, Green, and Yellow Belts. Each has a different job to do in the course of quality control to help the group goals become reality.
What are Six Sigma Program Goals?
While the goals of the original Six Sigma program for Motorola focused on improvement of their manufacturing process, the evolution of this type of training led naturally into other areas of business and service. The ultimate goal is to reduce defects and improve performance enough that everything increases customer satisfaction. Higher customer satisfaction should, in turn, lead on to increased sales, new customers, less waste, cutting costs, and increasing profits.
One of the finer points included in Six Sigma training for quality control is to provide continuous efforts to eliminate any variations away from a specific process. The thought here is that any variations from the plan can introduce an opportunity for errors, mistakes, waste or defects to occur. In manufacturing or in business processes, there are measurable characteristics. These can be quantified, analyzed, and improvements can then be made, bit by bit, eliminating variations. For this plan to work, everyone from top managers down to materials acquisition personnel must be involved and on the same track.
How Does Six Sigma Work?
The measurability focus of Six Sigma training for quality control is one thing that sets this program apart from other quality control efforts. Involving all personnel and managers adds interest and passion for excellence to the workplace. Managers have increased stature as experts and leaders. Decisions are then made according to verifiable data rather than guesswork.
The actual name, Six Sigma, comes from the world of statistics. Operations within a “Six Sigma Quality” range are expected to bring a defect rate down to an incredibly low level of below 3.4 defects per million opportunities. Any Six Sigma program has that target for a goal, or better.
The acronym DMAIC is used in Six Sigma training to define the program steps, which are:
1. Defining goals and the current process being used.
2. Measuring and collecting data about the current process.
3. Analyzing that data thoroughly to determine that all pertinent factors are included.
4. Improving any processes following analysis of the data.
5. Control of the process to assure that no variations occur, or if they are found, they are immediately corrected before any defects may occur.
Six Sigma Training Leads to Higher Customer Satisfaction
To achieve what the customer wants is the highest priority that will lead to better customer satisfaction and achievement of the program goals. Those goals must be defined, measured, analyzed, and a new plan designed. Finally, verification of the design is done with a test process before final production. Analysis and watchfulness continue as actual production is in progress.
It is easy to see how Six Sigma Training for quality control can greatly improve customer satisfaction. If production processes or service provisions are created and fine-tuned according to what the customer wants, there should be high satisfaction. During production or provision of service, all eyes are focused on the client’s project, with customer satisfaction as the ultimate goal. Everyone looks for possible variations from the stated plan to help avoid defects and errors. It is far better to have everyone on the project on the same page than to just have one manager running around trying to enforce high quality standards on a group.
Each person in the organization has a specific role to play, that is, their “Belt” level and duties. Leaders guide the others, and managers are viewed as leaders rather than task masters. All energies are devoted to quality control and optimum efficiency to cut costs and eliminate waste, defects, and errors. Six Sigma training for quality control is here to stay because it is a proven program that works.
