Successful Projects from the Application of Six Sigma Methodology

Abstract

This chapter describes briefly the Six Sigma Methodology (SSM) phases and Key factors for the effective implementation as well as the important tools. SSM was first introduced by Motorola in the 1980 s to improve product and service quality through the waste and variance reduction (Pyzdek, 2003). The SSM is a systematic way to solve problems with individual projects to attain better profitability. The SSM main objective is to reduce the number of defective parts to as low as 3.4 parts per million. The objective of this chapter is to show that taking into account the key factors and applying the right tools profitable results can be obtained. Three different application cases are used to illustrate the methodology throughout the chapter and were conducted in twin plants in the Juarez area where the authors participated. The SSM is structured in a five steps or phases in order solve successfully quality problems. These five steps or phases are known as, Define, Measure, Analysis, Improve and Control or DMAIC procedure. This paper describes these steps and illustrates the Key factors and tools that are needed for successful applications. The cases are related to applications that have been published previously (Valles et al., 2009a, 2009b, 2009c) They are design and the Improvement of Binder manufacturing process, Improvement of automotive speakers manufacturing process and the implementation of SSM for the manufacturing of a circuit that is used in inkjet printer cartridges. The three illustrative applications were successfully implemented by considering the key factors and important tools used throughout the deployment of the SSM. Also, some fundamentals were included such as basic definitions and philosophy, efficient communication, team work, training and management involvement and commitment. Beside the defective part reductions, some other important results were observed in the implementation process, such as culture change, trained employees and better human resources, and better project management skills. In conclusions, there were changes for the better in all the organizations where the SS implementations were conducted.