General
Due to increased globalization and constant technological advances and other competitive pressures, the organizations have to accelerate the pace of change to adapt to new situations. This climate introduces opportunities and threats and Organizations have to innovate and strive for operational excellence. Six Sigma is the most popular quality and process improvement methodology which strives for elimination of defects in the processes whose origin is traced back to the pioneering and innovation work done at Motorola and its adoption by many companies including GE, Ford, General Motors, Xerox etc. The primary objective of Six Sigma is to reduce variations, in products and processes, to achieve quality levels of less than 3.4 defects per million opportunities (DPMO). The important point to be noted is reducing the defects involve measurements in terms of millions of opportunities instead of thousands. Six Sigma is a culmination of several decades of quality improvement efforts pursued by organizations world over due to pioneering work done by quality Gurus Shewart, Deming, Juran, Crosby, Ishikawa, Taguchi and others. Dr. W. Edward Deming, who is considered by many to be the “Father of modern Quality movement”, was instrumental for transforming post war Japan into an economic giant because of helping for systematic introduction of quality improvement measures by Japanese companies. Dr. Deming had advocated popular quality improvement methods such as Total Quality Management (TQM), Plan-Do-Check-Act methodology, 14 point rules and elimination of 7 deadly sins and he helped organizations to achieve operational excellence with much customer focus. Later many US companies have gained much from Japanese experiences and ideas on quality improvement concepts. The Six Sigma concepts and tools used can be traced back to sound mathematical and management principles of Gauss, Taylor, Gilberth and Ford for their contributions like Sigma and Normal distribution (Gaussian distribution),Taylor’s Scientific Management, Gilberth’s ‘Time and Motion study’ and Ford’s mass production of cars using ‘Assembly line ‘ system. Six Sigma when coupled with ‘Lean Principles’ is called ‘Lean Six Sigma’ which professes eliminating waste in process steps by using ‘Lean Tools’ which is based on Toyota Production System(TPS) which enhances value in Six Sigma implementation one step further by increasing speed by identifying and removing non-value adding steps in a process. Execution of Lean Six Sigma project uses a structured method of approaching problem solving normally described by acronym ‘DMAIC’ which stands for Define, Measure, Analyze, Improve and Control. Many organizations have achieved phenomenal success by implementing Lean Six Sigma. Lean and Six Sigma are conceptually sound technically fool proof methodologies and is here to stay and deliver break through results for a long time to come. Motorola had celebrated 20 years of Six Sigma in the year 2007 and as per Sue Reynard in an article in ISixSigma-Magazine,” Motorola is a company of inventions and Six Sigma which was invented at Motorola is a defect reduction methodology that aims for near perfection has changed the manufacturing game of Motorola, but it didn’t stop there. As the Six Sigma has evolved during the ensuing 20 years, it had been adopted worldwide and has transformed the way business is done”.