Dr.N. Ganesan

You can use Z-value, Hypothesis testing control limits along with actual range of deviation both mean and std.deviation observed to see whether process is within 3 sigma or 6 sigma limits. It is not tough to combine and set sigma limits and look for opportunities to improve.

You don’t need to wait only for Non-conformances to start a Six Sigma Project. Process operating efficiency, costings, savings, cycle time, FMEA etc., could throw you up further to a robust design, process, with further savings. ISO 14001 procedures alone need not be targeted to do that. Six Sigma for that matter any continual improvement is related to process and even increasing any small incremental level is an achievement. Start with Sigma level, or OEE, Cycle/Takt time, RPN to find out whether you can start a project rather than starting from only Non-conformances.

Definitely reducing energy usage can be a Six Sigma project to have energyefficiency and cost reduction together. Costings of the system will be more of business evaluation and there without compromising the achieved quality, if you have scope to reduce the cost or steps you can consider still.

It depends on the kind of survey to go to this vigorous level. I always differentiate between a statistical decision and business decision. When you reject a null hypothesis itself you have disapproved the claim made by others. Further what is your interest, you can collect more data and plot as suggested Box-plot or ven histogram to decide on your own. Still if you want ot be perfect, the moment you say non-normal there are methods to make it normal and then proceed for the testing. Use one of that and there itself you will know the difference for e.g, Use Box-Cox transformation which will give you Lambda values for each of the data to make it normal and from that you could make out clear which Lambda you should trust than the other one.

When you say Sig Sigma project it should not differentiated in terms of GB or BB project from the company angle. Aim is to reduce the variability and bring more quality and financial savings also. Still you want to differentiate, I would say a BB project should be thorough professional leadership, project management, time management and implmentation of the improvement thought off and a definite financial impact to the company. You may do a GB project to showcause your skills acquired in Six Sigma and use that as a stepping stone for the next project.

I don't know whether your organizatin is registererd to ISO 14001 Environmental Management System. If you do that, automatically during the evaluation itself you will know your gaps with the environmental and regulatory requirements and most of those gaps you can take it as Six Sigma projects to have the robust system. Use DFSS if you haven't done the registration or DMAIC if you have already done it.

Lean is always complements any continuous improvement problems or issues. We need to get organized before getting to the bottom of the issue. Six Sigma targets variability and removes it with a very determined effort. No need to choose between the two and better to use both in any organization. From my experience I would say do Lean first and then parallel or otherwise, take many Six Sigma initiatives to root out your variabilities to have a high quality robust product/service. Still Lean will be required always, atleast in the form of 5S to keep your house in order. While ISO insisted on continual improvement in organizations, Lean took a special attention through 5S, Kanban , Pull-system, Poka-yok and other tools. It helps Six Sigma to provide data also in a very methodical manner without any confusions if you have implemented Lean first.

Name it as “EASY PRO-TRAIN” Dr.N.Ganesan

Six Sigma's main strength is about Project Management & Statistics and they should allow one like MBA or QA Professional or a Statistician who has done credited courses or accomplishments in both front to go for Black Belt . When even a basic degree is not demanded for Six Sigma in many places, it is time they relax the rigid rules. Unfortunately it is not possible and accepted in most institutions.

You can plan for DFSS to make the design itself robust avoiding all foreseen failures with FMECA, conducing DOE and use QFD to know all customer/process requirements for a robust product.

Process capability is more accurate to establish and control precise in the machine related processes. We can control with various devices and automation, process steps designed accurate to meet the tolerances. Cp and Cpk gives the natural process capability after establishing statistical process control. We can more or less say with accuracy it is machine capability to produce the quality products to the tolerance. It is normally accepted in the industries to expect Cpk>1.33 for a very capable process. In the case of Six Sigma, sigma levels we use it combining with DPMO to look for continual improvement projects. Variability if it occurs, and if there is an opportunity need to be identified with performance data, rejections and evaluation of financial impact of type of scra/waste produced. In the case of Cpk, Ppk, SPC provides a wider varrieties of knowing the established causes, detect and control along with hourly chasrts established, then and there if we had established a long-range capability. Both have different purpose and should not be mixed with any short-cut formulae .

You need to have some dedicated Statistical package software like Minitab first to quickly use your data for analysis and store in the project format itself. You have what is called Quality companion along with Minitab. You have to invest on that. If you are comfortable only with Excel still you have dedicated softwares Sigma XL etc....