Introduction to Six Sigma

A statistical measure that shows how many standard deviations a data point is away from the mean.

The distance between the mean (average) of a process and a specification limit, expressed in standard deviations.

A process that achieves a standard deviation of 6 times the mean, leading to a very low defect rate.

The highest acceptable value for a product's characteristic.

The lowest acceptable value for a product's characteristic.

A type of chart used to monitor process behavior and identify potential problems.

Charts used to analyze and monitor continuous data, such as measurements or dimensions.

Charts used to analyze and monitor discrete data, such as counts or frequencies.

A flaw or imperfection in a product or process. Multiple defects can be found in a single unit.

A product with one or more defects that make it unacceptable or nonconforming to specifications.

Any stage or aspect involved in the production process, from raw materials to shipping.

The number of potential issues or flaws that might occur during the production process.

A measure of quality performance that calculates the average number of defects found in each unit produced.

A measure of quality performance expressed as the number of defects found per million opportunities. It reflects the overall quality of the process.

A metric that measures the number of defective units produced per million units.

A measure used to understand the overall efficiency of a process by calculating the percentage of units that pass through each stage without defects.

A structured approach to product or process design that aims to improve quality and reduce defects before production starts.

A set of tools and techniques used to analyze and improve the voice of the customer (VOC) during the Define phase of DFSS. It helps understand customer needs and wants.

A systematic approach to testing factors that influence a product or process's quality. It involves conducting experiments to identify optimal settings.

A method for creating prototypes quickly and iteratively during the design process. It allows for rapid testing and feedback.

A design philosophy that minimizes variability in manufacturing processes and products to achieve high quality and reliability.

A structured approach to designing systems that are robust, reliable, and easy to maintain. It emphasizes clear functional requirements.

A method for analyzing and resolving design problems by leveraging a database of solutions. It helps overcome technical challenges in product design.

A set of design practices that aim to ensure a product or process meets specific requirements, such as manufacturability, assembly, and cost.

A problem-solving approach that emphasizes a deep understanding of the user's needs and challenges. It involves brainstorming, prototyping, and testing.

A structured process for analyzing systems and their interactions to understand their behavior and identify potential improvements. It helps understand the big picture.

Green Belts complete 40 to 160 hours of coursework and participate in at least one Six Sigma project.

Black Belts require 160 to 360 hours of coursework and must complete at least one project.

Master Black Belts undertake 500 to 1,000 hours of training and must review completed projects to demonstrate their mastery of the subject.

Green Belts mentor White Belts and Yellow Belts.

Black Belts mentor Green Belts, White Belts, and Yellow Belts, reflecting their advanced knowledge and experience.

Master Black Belts mentor Black Belts, Green Belts, and Yellow Belts, and they typically have the highest level of expertise and leadership within the Six Sigma framework.

Motorola introduced a structured approach to quality management emphasizing statistical analysis and process improvement.

Motorola's certification program categorized skills into belt levels, creating a clear hierarchy within Six Sigma roles.

A measure of process performance representing the number of defects per million opportunities (DPMO). A Six Sigma process aims to achieve a DPMO of 3.4 or lower, indicating near-perfect quality.

A statistical tool used to monitor process stability and identify deviations from the desired performance. It uses a central line, upper, and lower control limits to track variation.

A crucial step in Six Sigma projects that aligns customer needs with critical quality requirements. It involves translating the Voice of the Customer (VOC) into measurable and actionable factors.

A methodical approach to improving quality and reducing defects in products and processes. It involves a series of defined steps and tools to identify and eliminate root causes of variation.

This index measures how well a process's output is centered within the acceptable range defined by the upper and lower specification limits.

A six Sigma process aims for a level of performance that results in only 3.4 defects per million opportunities. This indicates incredibly high reliability and consistency.

The Voice of the Customer (VOC) represents customer expectations and requirements, while the Voice of the Process (VOP) reflects the actual performance of the process. Aligning VOP with VOC ensures customer satisfaction.

These limits represent the range of values that are considered typical for a process, based on historical data. They help identify if the process is running stable or exhibiting unusual variations.