Post on 29-Mar-2015
PMBOK® Guide / PMI® / PMP®-
6σ
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Six Sigma (or more recent: Lean Six Sigma) uses projects to attain dramatic improvements in production and services.
What are the commonalities and differences with PMI®‘s methods?
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PMBOK® Guide/PMP®
PMBOK® Guide and Six Sigma – Basics
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What can we learn from Six Sigma?
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PMBOK® Guide/PMP®
PMBOK® Guide and Six Sigma – Basics
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Contents
1: What is Six Sigma?2: What Six Sigma Does
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PMBOK® Guide/PMP®
PMBOK® Guide and Six Sigma – Basics
1: What is Six Sigma?
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Six Sigma was based on groundbreaking work of Dr. Walter Shewhart, between the two world wars at Hawthorne, Il, USA.
Dr. Shewhart was the inventor of modern quality control based on statistics.
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1: What is Six Sigma?
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1: What is Six Sigma?
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Dr. Shewhart recommended to strive for 3σ quality.
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1: What is Six Sigma?
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3σ 2σ 1σ 1σ 2σ 3σμ
1: What is Six Sigma?
Gaussian standard curve
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Motorola (1986, Bill Smith), GE and other companies found 3σ insufficient for modern, complex products:
With growing numbers of items, production yields go down to fast.
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1: What is Six Sigma?
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1: What is Six Sigma?
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1: What is Six Sigma?
A special problem: Chip wavers had only 30% and less production yield. © image: Steve Evans
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Over time, processes get worse, e.g. by wear and tear of tools between to replacement cycles.
This is sometimes described by allowing a 1.5σ process shift.
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1: What is Six Sigma?
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A new quality goal was defined:
Further reduce the error level by a factor of ~1/1,000, even including the process shift.
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1: What is Six Sigma?
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1: What is Six Sigma?
3σ 2σ 1σ 1σ 2σ 3σ
~3,000 DPMO
3σ
DPMO: Defects per 1 million opportunities
6σ 4σ 2σ 2σ 4σ 6σ5σ 3σ 1σ 1σ 3σ 5σ
~3.4 DPMO
6σ Process
shift
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Once the 6σ quality goal of 3.4 DPMO has been achieved, even complex systems will attain a high yield.
Losses from low system quality (“cost of poor quality”, COPQ) will go down.
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1: What is Six Sigma?
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1: What is Six Sigma?
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1: What is Six Sigma?
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As of 2006 Motorola reported over US $17 billion in savings from Six Sigma.
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1: What is Six Sigma?
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1: What is Six Sigma?
Another application: Thousands of Dabawallas in India apply Six Sigma methods to deliver home-cooked food. © image: Steve Evans
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1: What is Six Sigma?
Some examples for Six Sigma application in DACH:
Engineering Automotive Logistics
Finance and Insurance
Medical Service
...
IT, ConsultingDistribution Production
2: What Six Sigma Does
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Six Sigma uses 2 phase modelsfor improvements:• DMAIC• DMADV (= DfSS)
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2: Methods of Six Sigma
Improving existing
products and services
Developing new
products and services
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Six Sigma uses various techniques:
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Pareto analysis
SIPOC analysis
2: Methods of Six Sigma
Business Process
MappingPick chart
Scatter diagram
CTQ tree
Check sheet
Control chart
General linear model
TRIZTaguchi
methods Cost-benefit analysis
Run charts
Stratification
ANalysis Of VAriance
Pareto chart Ishikawa (fishbone,
cause & effects) diagram
Chi-squared test Enterprise Feedback
Management (EFM) systemRoot
cause analysis
Process capabilityAxiomatic
designDesign of
experimentsRegression analysis
CorrelationHistogramsFailure mode
and effects analysis (FMEA)Kano
ModellingQuality Function
Deployment (QFD)5 Whys
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Six Sigma uses a special role model with popular certifications:
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2: Methods of Six Sigma
Six Sigma Champions:Project sponsorsand mentors
Six Sigma Master Black Belts:Full-time program managers, PMO heads and educators
Six Sigma Black Belts:Full-time projectmanagers
Six Sigma Green Belts:Part time projectcoordinators andassistants
3: From Six Sigma to Lean Six Sigma
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3: From Six Sigma to Lean Six Sigma
Six Sigma (Motorola, GE) Lean Manufacturing / Management (Toyota)
Striving for dramatic revolutions by means of projects.
Striving for continuous improvement.
Focus on improving output precision.
Focus on reduction of product stocks and process waste.
Goal: Reducing cost of bad quality. Goal: Short cycle times and just in time production and service.
Total Quality Management
History
Lean Six Sigma
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Six Sigma is “TQM on steroids”.
Lean applies a “pull” approach on production, i.e. it is driven from the output side, not input.
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3: From Six Sigma to Lean Six Sigma
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Experts today try to combine the methods to get the best of both worlds.
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3: From Six Sigma to Lean Six Sigma
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4: What can we learn from (Lean) Six Sigma?
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The project management approach of Six Sigma is rather simple:• 2 alternative phase models• No complex life-cycle descriptions• No process orientation for project management.
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4: What can we learn from (Lean) Six Sigma?
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Common elements shared with the PMBOK Guide:• Based on the Shewhart/Deming cycle (P-D-C-A)• Emphasis on customer satisfaction• Appreciation of stakeholder orientation• Team approach
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Common caveats shared with the PMBOK Guide:• Some companies have achieved quick wins
through implementations. • One should not expect repetiton in the own
organization. Benefits are rather long-term.
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4: What can we learn from (Lean) Six Sigma?
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The deeply hidden gem of Six Sigma:
The Implicit Focus onManagement Attention
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4: What can we learn from (Lean) Six Sigma?
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The role of the (Lean) Six Sigma Project Champion:• More than an Initiator – a true project sponsor• Deeply linked with the project, involved in it.• Takes an active role in critical processess like
change request management.
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4: What can we learn from (Lean) Six Sigma?
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The (Lean) Six Sigma Project Champion:• ...remove roadblocks.• ...assign, define and align roles.• ...develop the core structure of the Six Sigma
team.• ...own the process, guarantee implementation.
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4: What can we learn from (Lean) Six Sigma?
Thank you