Six Sigma Jobs by Peter Peterka

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Company Politics and Six Sigma by Peter Peterka

No grouping of human beings is without some amount of politics. Managing deployment of Six Sigma in your organization will unavoidably run into some personal issues and conflict. However, with deft handling of the personal and political issues that come up, along with patience and perseverance, your Six Sigma deployment will not get derailed.

Political factors that can affect a Six Sigma project include personal resistance to change, inflexible company policies, and incompatibility with existing organizational methods and goals. Not surprisingly, all of these factors also affect business processes of any kind. They are not unique to Six Sigma. This is one of Six Sigma's strengths: realistically acknowledging the way politics work in an organization. Six Sigma is not just number crunching. It understands the importance of and encourages the involvement of people throughout and at all levels of the organization working together toward a common goal. Six Sigma encourages planning, communication, and openness about processes, procedures, and information.

Many people see change, any change, as loss—a loss of their power or a loss of the security of the old way of doing things. Thus, people are prone to defend the old way, out of habit and out of unease. They wonder how change will affect them and what exactly happens behind the scenes and if they don't know, become apprehensive. This is a problem that can be overcome through communication. Six Sigma successes require clear and open communication at all levels. Any change in an organization will meet some resistance, either intentional or just from inertia. When management can effectively communicate that it is behind that change and can communicate the positive aspects of the change, resistance and “turf” politics can be countered and overcome.

Another problem is people who disregard the value and power of Six Sigma and consequently, they are reluctant to support Six Sigma projects. To the uninitiated, Six Sigma may appear similar to or simply an evolution of other quality programs. There have been so many quality improvement fads over the years. It is not surprising that people are now a little jaded. Others may see Six Sigma as solely another cost-cutting or productivity enhancement fad. This is a short-sighted view. Six Sigma is neither a fad nor just another quality initiative. It is a “way of life.” It is a multi-level, cyclical movement toward continual process improvement. The quality improvement fads sell themselves as cheap and easy quick fixes. The reality is that there are no quick fixes to significant process improvement. Six Sigma understands that; it is not a simple quick process. However, the right Six Sigma training and information will help people to understand that Six Sigma is significantly different; it is a robust continuous improvement strategy and process.

Once projects are begun, Six Sigma projects can become a battle of wills for control over which strategy, approach, or tool is used. Team meetings can devolve into arguments over which measurement to use, how it will be calculated, which charts will be generated, whether to use DMAIC or DMADV, etc. Six Sigma is not about making things more difficult. It is about using common sense to make things easier. It is certainly about recognizing that there is more than one road to improvement and more than one right answer to a problem.

In overcoming political problems, the leadership of senior management is critical. Successful Six Sigma programs are built on a solid organizational foundation. The organizational structure and system needs to be clearly identified and communicated to the entire organization to successfully implement Six Sigma Quality. Becoming a Six Sigma organization doesn't just happen. Planning and training goes into setting up a successful Six Sigma organization. Employee roles and responsibilities must be established and clearly communicated to all. For many companies successful in Six Sigma, the key factor has been the direct involvement of their top leaders.

Six Sigma is about getting everyone involved. A Six Sigma project forms a team of people who work together to identify problems and develop solutions. Such teams are not isolated teams rearranging the world for everyone else to live in. These teams are serving the organization by employing the skills and tools they have learned to increase quality and reduce defects. Instilling the team concept along with expert training will go a long way toward solving potential political troubles in your organization.

Peter Peterka is a Master Six Sigma Black Belt for Six Sigma us and has implemented Six Sigma in a variety of organizations. For additional information for Six Sigma Online Training please contact Peter Peterka at http://www.6sigma.us

Communication in Six Sigma by Peter Peterka

Deploying Six Sigma means entering a period of significant change in your organization. Productivity and morale almost always suffers in times of great change. The requirements of change and adaptation and the very human fear of the unknown add to stresses of the work environment. In these times, communication becomes more important than ever.

Communication throughout a Six Sigma project is very important because the power and scope of Six Sigma demands a significant commitment from everyone in the organization. Six Sigma successes require clear and open communication at all levels to transcend departmental barriers that would otherwise cause confusion. In addition, any change in an organization will meet some resistance, either intentional or just because of inertia. When management can effectively communicate that it is behind that change and can communicate the positive aspects of the change, resistance can be countered and overcome.

Company leadership must be willing to give Six Sigma teams all of the tools and information necessary to apply Six Sigma concepts to their day-to-day activities. It is crucial in Six Sigma projects to clarify the rationale, expectations, goals, and sequence of steps in the process. Six Sigma teams with clear, written goals accomplish far more in a shorter period of time than teams without them could ever imagine. This is true everywhere and under all circumstances. Documentation of the Six Sigma process is the opportunity to resolve any misunderstandings of the deployment. A schedule is developed that outlines the strategy to take the process from its current state to one that is within statistical control and in line with the company's Six Sigma goals. Roles need to be clearly defined in how individuals contribute to the schedule and strategy. Employees assess how they can contribute to the organization through the information they receive. A team's quality goals should be set to tie in with the overall company quality improvement goals. This happens only when the team has the knowledge they need.

Lack of clarity in communicating business information is probably more responsible for frustration and underachievement than any other single factor. It is unfortunately way too easy to not realize that communication is falling short of your organization's needs. Often senior managers sincerely believe they are adequately communicating with employees. However, managers can easily underestimate the number of issues on which employees need information and how much information they need.

How do you know what is important to employees and what to tell them? You need to put yourself in the position of the employees. If you were that person, what would be important for you to know to do your job? What would you be worried about in the current situation? What information would help you deal with change? How would you want to be told? You can't answer those questions yourself. You need input from the very people you are trying to understand. Communication is a two-way street—listening as well as talking. Asking a few individuals what is being said, what people are worrying and wondering about.

Also be aware that the way a person receives news can dramatically affect how he or she feels about it, so you need to choose the medium very carefully. E-mail can be perceived as cold and unfeeling, although it is useful for routine updates that don't have emotional overtones. Many messages are better delivered in person, either to individuals or to the team as a whole.

Communication skills take practice. Always be sure the message remains honest, clear and compassionate. Have integrity and build trust. Don't say what you don't mean. Don't promise anything that you cannot or will not fulfill. Above all, follow through on your commitments and promises. Nothing turns employees off more than feeling betrayed. Sincere, caring, and constant communication will form the basis for building employee engagement throughout Six Sigma deployment.
Peter Peterka is a Master Six Sigma Black Belt for Six Sigma us and has implemented Six Sigma in a variety of organizations. For additional information for Six Sigma Training and Six Sigma Consulting please contact Peter Peterka at http://www.6sigma.us/

Design for Six Sigma by Peter Peterka

Design for Six Sigma (DFSS) is the application of Six Sigma principles to the design of products and their manufacturing and support processes. Whereas Six Sigma by definition focuses on the production phase of a product, DFSS focuses on research, design, and development phases. DFSS combines many of the tools that are used to improve existing products or services and integrates the voice of the customer and simulation methods to predict new process and product performance.

DFSS can be compared to DMAIC (Design, Measure, Analyze, Improve, Control) and often the acronym DMADV (Define, Measure, Analyze, Design, Verify) is used to describe the strategy of DFSS. The precise phases or steps of a DFSS methodology are not universally defined. Most organizations will implement DFSS to suit their business, industry, and culture. DFSS methodology, instead of the DMAIC methodology, should be used when:
* A product or process is not in existence at your company and one needs to be developed
* The existing product or process exists and has been optimized (using either DMAIC or not) and still doesn't meet the level of customer specification or six sigma level
DFSS is a way to implement the Six Sigma methodology as early in the product or service life cycle as possible. It is a strategy toward extraordinary ROI by designing to meet customer needs and process capability. DFSS can produce the same order of magnitude in financial benefits as DMAIC. But it also greatly helps an organization innovate, exceed customer expectations, and become a market leader.

DFSS is the Six Sigma approach to product design—namely, designing products that are resistant to variation in the manufacturing process. Using DFSS means designing quality into the product from the start. You are preventing wasteful variation before it happens, thus being able to identify and correct problems early when the solution costs are less. A successful DFSS implementation requires the same ingredients as any other Six Sigma project: a significant commitment and leadership from the top, planning that identifies and establishes measurable program goals and timeline, and the training and involvement of everyone.

Planning for DFSS requires collecting the necessary information that will allow for error free production of defect-free products and processes that satisfy the customer profitably. DFSS attempts to predict how the designs under consideration will behave and to correct for variation prior to it occurring. That means understanding the real needs of your customers and translating those needs into vital technical characteristics of the product and ultimately into critical to quality (CTQ) characteristics of the product and process. You can then use design of experiments (DOE) to develop a robust design that optimizes efficiency and reduces defects.

Valid and reliable metrics to monitor the progress of the project are established early in the project, during the Measure phase if using DMADV. Key inputs are prioritized to establish a short list to study in more detail. With a prioritized list of inputs in hand, the DFSS team will determine the potential ways the process could go wrong and take preemptive action to mitigate or prevent those failures. Through analysis, the DFSS team can determine the causes of the problem that needs improvement and how to eliminate the gap between existing performance and the desired level of performance. This involves discovering why defects are generated by identifying the key variables that are most likely to create process variation. Failure Mode and Effect Analysis (FMEA) and Anticipatory Failure Determination (AFD) can be used for both the design of the product and the design of the process.

DFSS provides a structured way to constructively use the information learned from these analyses. Armed with real data produced by the DFSS process, you can develop competent manufacturing processes and choose processes that are capable of meeting the design requirements. Further analysis can verify and validate that the product design will meet the quality targets. This can be accomplished through peer reviews, design reviews, simulation and analysis, qualification testing, or production validation testing.

The benefits of DFSS are more difficult to quantify and are more long-term. It can take over six months after the launch of the new product before you will begin to see the true measure of the project improvements. However, the eventual return on investment can be profound. This is especially true when the organization can use the DFSS project as a template for fundamental changes in the way it develops new products and processes across the organization.

Peter Peterka is a Master Six Sigma Black Belt for Six Sigma us and has implemented Six

Sigma in a variety of organizations. For additional information for Six Sigma Training and Design for Six SIgma please
contact Peter Peterka at http://www.6sigma.us

Six Sigma solves problems with an unknown solution by Peter Peterka

Six Sigma is a powerful business improvement strategy. It helps your organization to identify, reduce, and eliminate defects from any product, process, or transaction. More than a "quality" program, Six Sigma is a flexible and dynamic continuous improvement strategy and process initiative that helps your organization uncover solutions.

For example, you may know that a particular process at your organization is not meeting customer specification or is otherwise not performing adequately. However, the solution is not apparent up front. There are many variables that could be causing the defect in the process. How do you determine what specific action you can take to improve your process and reduce defects? Finding that unknown solution is what Six Sigma does best.
Six Sigma is not a pre-packaged one-fits-all solution. Six Sigma is a process that doesn’t impose a particular outcome but discovers the previously unknown solution to a problem. It uses a structured systems approach to problem solving that achieves strategic business results through an intelligent step-by-step process. A structured thinking process helps solve problems better than an ad hoc, blank page approach.

Six Sigma leads organizations through five-steps of realization:
1. We don't know what we don't know.
2. We can't do what we don't know.
3. We won't know until we measure.
4. We don't measure what we don't value.
5. We don't value what we don't measure.

By using Six Sigma to identify and correct major problems you create real data that uncovers previously unknown solutions to problems – solutions that you most likely would not be able to discover except through the Six Sigma methodology. What drives this process is the DMAIC method. DMAIC is an acronym for five interconnected phases of a Six Sigma project: Define, Measure, Analyze, Improve, Control. By going through the structured phases you discover the unknown solution to your quality problem.

First you identify the problem you need to solve. At the Define stage of a project, you should have a defined issue or problem you wish to overcome and improve. Once a process is selected as a candidate for improvement, a problem statement is developed and the objective or desired outcome is defined. Progress measures are established and a cost/benefit analysis is performed. Also during the Define phase, you highlight what the project is supposed to do and how it is supposed to do it and what metrics apply. With a clear measurable set of indicators, the Measure phase studies the process to determine the key process steps and variables to determine the potential ways the process could be going wrong.

After measurements are gathered, the data is analyzed to discover what is causing process variation. Once problem causes are determined in the Analyze phase, you find, evaluate through testing, and decide on creative new improvement solutions. As you move through the Analyze and Improve stages of the process you will identify various process improvement scenarios, and determine which solution has the best net benefit impact to the company. Most likely, the variation is from a completely unknown source. Without going through the Analyze and Improve stages you would not have known what improvement was required, much less what categories of variables were being affected!

Six Sigma is about tackling problems with an unknown solution. Six Sigma experts know that there are no one-size-fits-all solutions. Six Sigma training provides participants with enhanced problem-solving skills, with an emphasis on the methodology for identifying and creating solutions. As Six Sigma practitioners, you need to be agnostic. Use the best tools from all of the various methods and apply the right solution to the right problem. Through being agnostic and open-minded you will discover solutions through observation and data rather than just impose solutions from the outside. This enables you to use the best from all of the various methods and tools available and apply the right solution to the right problem. You will be amazed at how well THAT works!

Peter Peterka is a Master Six Sigma Black Belt for Six Sigma us and has implemented Six Sigma in a variety of organizations. For additional information for Six Sigma Online Training please contact Peter Peterka at http://www.6sigma.us/

The Effectiveness of Online Training by Peter Peterka

Online training is known by numerous names and acronyms—computer-based training (CBT), web-based training (WBT), cyber-training, distance learning, e-learning, etc. By whatever name, online training is a method of delivering training through an electronic medium without the immediate presence of a human instructor. By taking advantage of technology, online training can be more cost effective by delivering more knowledge in a more flexible and efficient manner.

There are distinct advantages to online training that may apply to your organization. With an online training course you have the ability to consolidate education and training across geographical and time constraints. Courses can be delivered to people in different offices without the expense of travel and with less interruption of work schedules. For individuals with busy schedules, online training courses offer the flexibility of being available when the people are able to take the training.

This flexibility is the strongest facet of online training and the flexibility extends beyond scheduling. For many people, an online training course supplies material in a more palatable manner then instructor-led courses. This certainly isn’t true for everyone, but the power of online training to help many people makes it an important tool for your training program. Online training is self-paced and includes interactive tutorials, questionnaires, case studies, self-assessment, and other features that easily assimilate to individual learning styles. Because people have more control over their training experience, online training offers the opportunity to learn in a non-stressful environment.

An online training course combines the advantages of uniformity in training and self-paced training. The basic course is the same for each trainee (while still offering you the chance to tailor instruction more easily) but can be delivered to different people at different times. While a human instructor is only available a limited time, online training materials don’t “go home” and trainees can review the subject matter as needed or desired. Support can be supplied via e-mail or phone.

Online training most likely will not require any additional equipment at your location. Training is delivered through existing computers and an Internet connection. Most online courses will run through any Internet browser on any operating system. You will need to dedicate newer and powerful computers to the training is the course has graphics, sound or video. Don’t make the mistake of using old castoff computers as your training computers. That will just make your trainees frustrated.

Still, being in an electronic format alone does not ensure that training is effective. How do you make the online training course effective for your people? To be effective, an online training course must be interactive without being messy. Bells and whistles are not always a benefit if they overburden the user. The course material and its interface should be streamlined. So, while you can incorporate video and audio instructions, interactive simulations, testing modules, and the like, the question you should be constantly asking is: “does this add to the substance of the course?” Does the way information is being portrayed supplement the learning object of a particular topic. If it does not add to the real content of the course and increase the knowledge of your trainees, then all of the flash and pizzazz will end up being more distracting than helpful. Likewise, always be sure that the learning interface, navigation graphics, and control buttons are easily understood and useable.

The self-paced flexibility of online training can also be a negative as well as a positive. Flexible should not mean unstructured. Yes, people can take the training when it fits their own schedule, but that schedule should still be a structured, set time, not just starting and ending when they feel like it. Thus, you probably want to have the online training course only available on computers inside a dedicated training room. Assign specific times for trainees to come for training in an environment where they can train undistracted. Really, your online training environment should be similar to an instructor-led training environment—a room conducive to learning and concentration where trainees can get the most out of their time.

When designed and carried out systematically and in an organized manner online training can be highly effective. Either as an addition to or a replacement for the face-to-face classroom environment, online training can be a strong part of your organization’s training environment.

Peter Peterka is a Six Sigma Master Black Belt

for Six Sigma us and has implemented Six Sigma in a variety of organizations. For

additional information for Six Sigma Online Training please contact Peter Peterka at http://www.6sigma.us

Six Sigma Deployment in Smaller Organizations by Peter Peterka

Six Sigma is not just for large multinational corporations. While there are difficulties inherent in implementing Six Sigma in a small company rather than a large business they can be overcome. Six Sigma can work in any size business because the nature of Six Sigma is dependent upon characteristics inherent in any business, not on the size of a business. Smaller organizations frequently are short on resources and expertise in change initiatives. However, they also have more flexible process flows, a shorter decision-making chain, and higher visibility of senior management. Smaller organizations can actually effectively establish Six Sigma faster than large businesses if deployment scope is correctly managed.

Scope of Deployment

Six Sigma is designed for all-inclusive deployment across an organization. However, s maller organizations do have constraints that limit their ability to initiate a large scale Six Sigma implementation. If your organization does not have the resources to create an infrastructure for organization-wide Six Sigma deployment then start with a pilot program.

One of the beauties of Six Sigma is that its central methodology is scalable. Six Sigma, emphasizes intensive training and extensive analysis—qualitative characteristics that work regardless of the size of the organization. Likewise, Six Sigma DMAIC (design, measure, analyze, improve, and control) discipline s work no matter the size of the organization or even the size of the Six Sigma project. Even a small Six Sigma project can yield significant results. Breakthrough improvements in processes and bottom-line profitability come not from quantity of resources, but the quality and the intelligence with which they are employed.

Small and medium-sized organizations may not have the resources of larger companies; however, in most cases, smaller organizations can be more nimble, flexible, and focused on results. Approaching initial implementation of Six Sigma through a pilot program will yield tangible results without overwhelming your resources from a small “quick-hit” project. These results can then be replicated throughout the organization, in many cases even faster than in a large organization.

Issues Critical to Smaller Organizations

When deploying a pilot Six Sigma project there are several important issues to consider inherent to smaller organizations. First, the choice of a project is critical. The pilot project will set the tone for Six Sigma deployment, so it should be a good one that can show significant and visible results in a reasonably short period of time. The project must clearly address one or more business goals thereby contributing to one or more core enterprise measures. Each project must also be completable within three to four months, so careful upfront scoping is essential. Projects must be continually tracked and updated for line management during existing business reviews.

Another issue is training. In smaller organizations, training budgets and especially time available to devote personnel for training is limited. Thus, it is not always practical for personnel to be absent from their day-to-day duties to attend months of training. Fortunately, there are some Six Sigma consultants who can deliver required Six Sigma training in an accelerated format and even onsite. Thus, smaller organizations can give their people the needed training with less disruption to their normal business, improving internal synergy while providing greater organizational flexibility.

Six Sigma implementation teams can encounter critical resource restrictions, often due to a personnel limitation where people are available for project functions only on a part-time basis. It is essential at project inception that the right people are involved, doing the right things. A small but committed force of the right people with proper training, given the proper authority will go far in getting things started. Good and fluid communication is also critical.

Upon successful completion of the Six Sigma pilot, the scale of the deployment is then expanded to other areas of the organization, incorporating the lessons learned from the pilot project. Just as it is much harder for a large ship to turn than a small ship, smaller organizations can change and adapt more quickly than large organizations. That does not mean that small organizations will automatically be successful when deploying Six Sigma, but making change take place and getting buy in to the changes are easier.

Peter Peterka is President of Six Sigma us. For additional information on Six Sigma Deployment or other Six Sigma Master Black Belt project programs contact Peter Peterka http://www.6sigma.us/

Six Sigma Tools by Peter Peterka

Statistics are at the heart of Six Sigma’s powerful methodology for quality improvement. It pays to get to know some of the most important of the Six Sigma statistical tools.

Control Charts
The control chart is the fundamental tool of statistical process control; a proven technique for improving productivity. It monitors the variation of key characteristics and indicates the range of variability that is built into a system. Control charts provide diagnostic information about process capability that can be used to analyze variation in process data to demonstrate whether a process is operating consistently. The bounds of the control chart are marked by upper and lower control limits that are calculated by applying statistical formulas to data from the process. Data points that fall outside these bounds represent variations due to irregular causes, which can then be identified and eliminated. Control charts are effective in defect prevention and will help ensure that your process performs consistently. From them, you can, in a precise manner, monitor, control, and improve on process performance over time. This will allow you to be able to predict fluctuations, lower costs and ensure the process has a higher effective capacity.

Failure Modes and Effects Analysis (FMEA)
FMEA is a powerful structured approach that helps you to identify and counter weak points in the early conception phase of products and processes. Using FMEA allows you to analyze any system or subsystem in manufacturing or service industries in the early stages of the process. This systematic methodology identifies potential failure modes in a system caused by either design or process deficiencies. It also identifies critical or significant design or process characteristics that require special controls to prevent or detect failure modes. FMEA improves the quality of products and services and processes by preventing problems from occurring. It documents and tracks action taken to reduce risk while it integrates with the DMAIC methodology.

Histogram
A histogram is used to graphically summarize the distribution of a data set. A histogram is constructed by dividing the range of data into equally sized segments. This data tool enables you to quickly and easily answer several important questions: what distribution does the data have? What is the most common system response? Is the data symmetric or does it contain outliers?

Pareto Chart
A pareto chart is used to graphically summarize the relative importance of the differences between groups of data. A pareto chart is constructed by dividing the range of data into groups. The vertical axis of the pareto chart is the cumulative percentage, and the horizontal axis of the pareto chart is the groups of response variables. Unlike the histogram, the pareto chart is ordered in descending frequency magnitude. The Pareto Chart allows you to focus your efforts to achieve the greatest improvements by identifying the largest issues facing the process. It identifies the 20% of sources that are causing 80% of the problems.

Peter Peterka is President of Six Sigma us. For additional information on Six Sigma Black Belt . or Minitab programs contact Peter Peterka
http://www.6sigma.us

What is Six Sigma Deployment by Peter Peterka

In the implementation of Six Sigma, an effective infrastructure lays the foundation for success. An effective infrastructure for your Six Sigma or Lean Flow change initiative in an organization requires a clear strategy and comprehensive planning.

Strategizing and Planning
The planning stage of a Six Sigma deployment is where you can gain valuable traction. A critical factor in a successful deployment is the selection and chartering of the project that link to the strategy of their organization. Project should be selected with an understanding of what areas within the business are struggling to meet performance goals in the standard areas of cost, capacity and customer service. A deployment meeting can be called to create a prioritized project list. Once the projects are selected, project leaders are identified and readied for training. The leadership team identifies process characteristics that have the most impact on quality–separating the “vital few” from the “trivial many.” With these characteristics identified the team can create a map of the process to be improved with defined and measurable, deliverables, and goals that will guide the project deployment.

Initialization
Once an organization initiates a Six Sigma program, it is very important for the organization to effectively deploy information about its target goals to employees. Involvement of top management and alignment of company leadership are critical. With the chief executive’s decision to proceed, a corporate-level deployment champion that reports directly to the chief executive should be identified. A set of policies, guidelines and rules must be developed with involvement of the deployment champion, one or more steering committees, and selected corporate departments such as finance, human resources, quality, communications and others.

Determining the current performance levels and setting goals for improvement are accomplished through an On-Site Assessment coupled with a Value Stream Assessment. The On-Site Assessment provides insight to the current directions of the business and the business metrics employed. The Value Stream Assessment provides detailed metric data for the processes within the business for use in aligning resources with projects.

Training
Establishing and executing Six Sigma training plans are also critical. Some organizations try to cut costs by training only some members of the project team. This may seem penny-wise but ends up being pound-foolish. Implementation of significant return on investment can be realized from an orchestrated deployment over a grass-roots effort. If your organization is considering sending more than ten people through Green or Black Belt training, it is recommended that you consider a customized On-Site Deployment to maximize your return on training investment.

Project Mentoring
Organizations might insist on saving money by using Black Belts who are part-time.
However, successful completion of projects is increased when the Black Belt project leader can focus full-time on the project. It is important to get the right people involved doing the right things and the Black Belt should be available to assist everyone involved in the project. An organization will realize a much larger return on investment with dedicated resources. The Black Belt must also be a mentor to everyone on the team and develop a mentoring process. During the project, the Black Belt should continually Structure the team and its actions to best utilize the disparity in knowledge and techniques of the team members and increase project member morale. Chances of success is also improved when the Black Belt has a technical resource to review the project for use of the methods and for progress towards the desired goal. Mentoring can be accomplished through various means but should be conducted for no less than 2 hours per project per month.

An Ongoing Process
The implementation of Six Sigma must impact how people think and perform their day-to-day work. Continuous improvement processes, such as Six Sigma, means including people, gaining their involvement, and then supporting what they are trying to accomplish. Six Sigma asks for input on improvement solutions from all employees because it recognizes the value of creative solutions to problems from any and all sources. For real and lasting process improvement, that is how it should be. Thus, Six Sigma deployment is not a on-time thing; it is an ongoing activity.

Peter Peterka is President of Six Sigma us. For additional information on Six Sigma Deployment or other Six Sigma Master Black Belt project programs contact Peter Peterka http://www.6sigma.us

Communication in Six Sigma by Peter Peterka

Communication throughout a Six Sigma project is very important because the power and scope of Six Sigma demands a significant commitment from everyone in the organization. Six Sigma successes require clear and open communication at all levels to transcend departmental barriers that would otherwise cause confusion. In addition, any change in an organization will meet some resistance, either intentional or just because of inertia. When management can effectively communicate that it is behind that change and can communicate the positive aspects of the change, resistance can be countered and overcome.

Company leadership must be willing to give Six Sigma teams all of the tools and information necessary to apply Six Sigma concepts to their day-to-day activities. It is crucial in Six Sigma projects to clarify the rationale, expectations, goals, and sequence of steps in the process. Six Sigma teams with clear, written goals accomplish far more in a shorter period of time than teams without them could ever imagine. This is true everywhere and under all circumstances. Documentation of the Six Sigma process is the opportunity to resolve any misunderstandings of the deployment. A schedule is developed that outlines the strategy to take the process from its current state to one that is within statistical control and in line with the company's Six Sigma goals. Roles need to be clearly defined in how individuals contribute to the schedule and strategy. Employees assess how they can contribute to the organization through the information they receive. A team's quality goals should be set to tie in with the overall company quality improvement goals. This happens only when the team has the knowledge they need.

Lack of clarity in communicating business information is probably more responsible for frustration and underachievement than any other single factor. It is unfortunately way too easy to not realize that communication is falling short of your organization's needs. Often senior managers sincerely believe they are adequately communicating with employees. However, managers can easily underestimate the number of issues on which employees need information and how much information they need.

How do you know what is important to employees and what to tell them? You need to put yourself in the position of the employees. If you were that person, what would be important for you to know to do your job? What would you be worried about in the current situation? What information would help you deal with change? How would you want to be told? You can't answer those questions yourself. You need input from the very people you are trying to understand. Communication is a two-way street—listening as well as talking. Asking a few individuals what is being said, what people are worrying and wondering about.

Also be aware that the way a person receives news can dramatically affect how he or she feels about it, so you need to choose the medium very carefully. E-mail can be perceived as cold and unfeeling, although it is useful for routine updates that don't have emotional overtones. Many messages are better delivered in person, either to individuals or to the team as a whole.

Communication skills take practice. Always be sure the message remains honest, clear and compassionate. Have integrity and build trust. Don't say what you don't mean. Don't promise anything that you cannot or will not fulfill. Above all, follow through on your commitments and promises. Nothing turns employees off more than feeling betrayed. Sincere, caring, and constant communication will form the basis for building employee engagement throughout Six Sigma deployment.

Peter Peterka is a Master Six Sigma Black Belt for Six Sigma us and has implemented Six Sigma in a variety of organizations. For additional information for Six Sigma Training and Six Sigma Consulting please contact Peter Peterka at http://www.6sigma.us/

Handling Statistical Variation in Six Sigma by Peter Peterka

The term “six sigma” is defined as a statistical measure of quality, specifically, a level of 3.4 defects per million or 99.99966% high-quality. To put into practice the Six Sigma management philosophy and achieve this high level of quality, an organization implements the Six Sigma methodology. The fundamental objective of the Six Sigma methodology is the implementation of a measurement-based strategy that focuses on process improvement and variation reduction through the application of Six Sigma improvement projects. Projects are selected that support the company's overall quality improvement goals.

A Six Sigma project begins with the proper metrics. Six Sigma produces a flood of data about your process. These measurements are critical to your success. If you don't measure it, you can't manage it. Through those measurements and all of that data, you begin to understand your process and develop methodologies to identify and implement the right solutions to improve your process. Six Sigma’s clear strength is a data-driven analysis and decision-making process—not someone's opinion or gut feeling.

Metrics lie at the heart of Six Sigma. Critical measures that are necessary to evaluate the success of the project are identified and determined. The initial capability and stability of the project is determined in order to establish a statistical baseline. Valid and reliable metrics monitor the progress of the project. Six Sigma discipline begins by clarifying what measures are key to gauging business performance, then it applies data and analysis to build an understanding of key variables and optimize results. Fact driven decisions and solutions are driven by two essential questions: What data/information do I really need? How do we use that data/information to maximize benefit?

Six Sigma metrics are more than a collection of statistics. The intent is to make targeted measurements of performance in an existing process, compare it with statistically valid ideals, and learn how to eliminate any variation. Improving and maintaining product quality requires an understanding of the relationships between critical variables. Better understanding of the underlying relationships in a process often leads to improved performance.

To achieve a consistent understanding of the process, potential key characteristics are identified; the use of control charts may be incorporated to monitor these input variables. Statistical evaluation of the data identifies key areas to focus process improvement efforts on, which can have an adverse effect on product quality if not controlled. Advanced statistical software such as Minitab or Statgraphics, are very useful if not essential for gathering, categorizing, evaluating, and analyzing the data collected throughout a Six Sigma project. Special cause variation can also be documented and analyzed. When examining quality problems, it is useful to determine which of the many types of defects occur most frequently in order to concentrate one's efforts where potential for improvement is the greatest. A classic method for determining the "vital few" is through a Pareto chart.

Many statistical procedures assume that the data being analyzed come from a bell-shaped normal distribution. When the data to be analyzed does not fit into a normal bell-shaped distribution, the results can be misleading and difficult to discern. When such data distribution is encountered, other statistical techniques can be used to assess whether an observed process can reasonably be modeled by a normal data distribution. In such cases, either a different type of distribution must be selected or the data must be transformed to a metric in which it is normally distributed. In many cases, the data sample can be transformed so that it is approximately normal. For example, square roots, logarithms, and reciprocals often take a positively skewed distribution and convert it to something close to a bell-shaped curve. This process will uncover significant statistical variation, separating the important data from meaningless data “noise.”

Once the data is crunched and a problem’s root causes are determined, the project team works together to find creative new improvement solutions. The data is used and relied upon—it is the measurements of the realities you face! Yet it is smart measurement and smart analysis of the data—and above all the smart creation of new improvement solutions and their implementation—that create real change. The Six Sigma statistical tools are only the means to an end and should not be construed as the end itself. Using tools properly is critical to getting the desired result. Through a successful use of statistics in uncovering significant data, Six Sigma will drive an organization toward achieving higher levels of customer satisfaction and reducing operational costs.

Peter Peterka is President of Six Sigma us. For additional information on Six Sigma Master Black Belt or Minitab Training programs contact Peter Peterka http://www.6sigma.us

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