All Features
Steve Wise
Some folks like to use control charts to analyze gauge study results. When using a control chart in this manner, one can assume that the chart should represent a series of gauge studies conducted over a period of time. In this example, let’s say that each morning a gauge is verified by recording…
For the last Brain Teaser, in an interesting spin, sample size was defined as a time window. A is the correct response. The underlying data type falls into the category of defect counts (complaints) within a constant area of opportunity (one hour). These data, of course, follow the…
A certain company has a complaint department that answers calls for three unique products. Because of failure rates inherent to each product type, some products have a higher expected complaint rate than others. Calls are tallied each hour and categorized by product type…
Since “Sick Sigma” was published in April 2006, the public has become much more aware of Six Sigma’s failings. There is little risk today of being burnt at the stake for pointing out Six Sigma’s many faults. Last fall, even Dilbert discredited Six Sigma, pointing out that Six Sigma…
An introduction to Six Sigma for direct marketing Six Sigma methods, used correctly and thoroughly for continuous improvement of direct marketing sales, can produce remarkable results:1. At a university work-force education program, total registrations doubled in three years through…
Thomas R. Cutler
In a repetitive manufacturing environment, Six Sigma’s quantification is much easier than in the engineer-to-order (ETO) manufacturing environment, where no two products are identical.
Six Sigma is a program that affects the entire company. What have been missing for ETO manufacturers are the…
In the last InsideSixSigma issue, we published a brain teaser by Steve Wise, who proposed a scenario and asked you to pick a chart that best described the situation in a manufacturing operation. Here, Wise gives the correct response and comments on the wrong ones. Correct response The…
Steve Wise
In a certain operation, a part is subject to a high-temperature curing cycle. The ideal curing scan is illustrated in the chart below. The oven chamber begins at room temperature, ramps up to a conditioning temperature of about 80 degrees, dwells for four minutes, ramps up again to the curing…
Tony Coray
One of the latest trends in the ongoing evolution of Six Sigma is its rising popularity among college students and its appearance in universities’ curricula. These courses are exposing students to the power of data-driven quality improvement and, in many cases, giving them firsthand…
David Schwinn
Once upon a time, in a real, live U.S. corporation, top management decided that Six Sigma was a good idea. They trained up many Black Belts to lead projects to produce documented savings as defined by the existing accounting system. To encourage people to be successful, the Black Belts—…
All too often FMEA (Failure Modes and Effects Analysis), DFMEA (Design, Failure Modes, and Effects Analysis) or FMECA (Failure Mode, Effects, and Criticality Analysis) ends up costing a company hundreds or thousands of dollars to prepare and returns nothing by way of payback, increased…
Dr T Burns
In 1633, opposition to the common viewpoint could mean death. This was the case with Galileo when he proposed that the Earth revolved around the sun. He was tried for heresy. Of course things are different today. People who question dogma are no longer burnt at the stake. Instead, they’re branded…
David C. Crosby
Zero defects is an idea that was discovered in the early 1960s. It was articulated by Phil Crosby and first implemented at the Martin company in Orlando, Florida. Zero defects enjoyed widespread popularity until the mid 1970s, and almost every major company and their suppliers had a zero-defects…
Gregory Roth II
I, for one, am tired of the quality flavor of the month. It isn’t quite that bad but it seems like it at times. Have you been through statistical quality control, TQM, total quality speed, re-engineering, zero defects, quality circles, SPC, Motorola Six Sigma, AlliedSignal Six Sigma, GE…
Steven Ouellette
“The great aim of education is not knowledge but action.” Herbert Spencer (1820 – 1903) What’s distance learning? Six Sigma Black Belt training has long been the realm of the elite. It used to be so expensive and required so much time that only companies with the cash and resources to…
The purpose of process data analysis is to answer the question, "May the observed data fluctuations reasonably be attributed to common-cause variation?" The principal use of the Shewhart control chart is to guide efforts for process improvement by assisting in the discovery of peculiarities in the…
Ken Levine
Engaging your workforce is a major obstacle in a lean Six Sigma implementation. Only a limited number of employees will initially participate in Six Sigma improvement projects. It can also take one to two years before all employees participate in a lean kaizen event. It’s best to encourage…
Daniel S. Munson
The Empire State Building in New York City, with its 103 stories, 73 elevators, 2,500,000 feet of electrical cable and 6,500 windows, was built in 405 days. The framework rose at a rate of four-and-a-half stories per week. That’s nearly a floor a day. Most impressive was that the project came in…
Marilyn Fischbach
Deployment is one of the most critical elements of a successful Six Sigma program. Top-down support, champion training, wide publicity and Six Sigma awareness training for all employees are common components. In addition, employees selected to be Black or Green Belts must be trained and projects…
Thomas R. Cutler
Kanban, in its most simplifying role, is a visual signal (or cue) that something needs to be replenished. More specifically, lean manufacturers today use kanban to drive a process to make, move or buy the appropriate parts. Thus, kanban has become one of the fundamental building blocks of a pull (…
“Jim, how do we know that your project made any improvement?” asked the Six Sigma champion. The Black Belt candidate looked confused. “Um, the sponsor said he was happy with the outcome,” he offered. The members of the certification board looked skeptically at one another: “But the only metrics…
Tom Pryor
My twin grandsons celebrated their first birthday on July 1, 2001. And while the majority of people reading this article don’t know Alex and Austen, there is another set of twins celebrating their fifteenth birthday this year whose names are familiar. Born in 1986, they are Six Sigma and Activity…
Failure mode and effect analysis, or FMEA, is an attempt to delineate all possible failures, their effects on the system, the likelihood of occurrence and the probability that the failure will go undetected. FMEA provides an excellent basis for classification of characteristics such as identifying…
Scott Paton’s "The Chinese are Coming! The Chinese are Coming!" (Quality Digest, February 2005) describes how China’s Chery Automobile Co. plans to undercut American automakers’ prices by up to 30 percent. The article professes that neither tariffs nor layoffs are the solution to the hemorrhage of…
As quality professionals, we frequently report such facts as proportions (percentages), process capability indices, averages and standard deviations as if we know what we’re talking about. But what’s our actual level of confidence? All of our observations and our understanding are based upon data…