Applications of Statistics SixSigma
Applications of Statistics SixSigma
Business Fields
Maged Younan
MBA, Six Sigma MBB
Table of contents
Abstract.............................................................................................................................. 3
In any business various decisions have to be made each day. Availability of reliable data
facilitates the decision making process. However, when statistical and graphical tools are
used to present and analyze available data, the decision becomes clearer, faster and more
accurate. In this paper we are discussing the Six Sigma methodology, its limitations and
its applications in the business field. Various examples of how six sigma tools can be
very useful will be presented covering the fields of Marketing, HR, Finance,
Manufacturing and Service. A case study will be also discussed in details showing how
the thinking methodology of six sigma was used to uncover the root cause of a problem
concerns and drive out defects” This is how Ford Motor company defined six sigma on
presenting their annual report in 2002. In this year Ford enjoyed a total savings of 52
Million USD due to implementation of six sigma. The “six sigma” is a methodology that
improvements through what is called: ”Six Sigma Projects”. Each “Project” follows a
certain road map for execution called the “DMAIC”. Throughout this road map a variety
of statistical and non statistical tools is used to understand and minimize the variation of a
critical process output. The steps of the “DMAIC” will be explained in a separate section.
Six sigma projects can tackle complex problems in all business areas including
Six Sigma started in Motorola in the mid of the nineteen eighties. When it started it was
mainly used and limited to fixing production defects. Later, the concept was extended to
deal with problems in all business areas, not only those in the shop floor. Motorola did
not invent any of the statistical or non statistical tools that are usually used in a six sigma
project but rather collected these tools and made them available as a kit that can be used
by green and black belts in solving problems. What Motorola did invent however is the
roadmap that should be followed in tackling problems. Six sigma methodology was then
conveyed Allied Signal and General Electric. Jack Welch who was the CEO of General
Electric is the one responsible for the great reputation and fame that the six sigma
methodology had acquired. Six sigma is very popular now in the United States in
Recently, Six Sigma started to be well known in some European countries; mainly in the
United Kingdom. Here in Egypt, around 100 business organizations are adopting and
The “sigma level” of a process or a company is a measure of performance. The higher the
performance of a process is the higher the sigma level. At a six sigma quality level the
nearest customer specification limit is six standard deviations away from the process
mean. The figure below explains that at this level the probability of having a defect –
Chart showing defects produced at 3 Sigma level compared to those at 6 Sigma level
people safety is involved as in aviation industry for example, six sigma quality is not
accepted.
The six sigma philosophy depends on the very basic equation of: Y = f (X). Meaning that
if we are trying to fix any process output “Y”, we should rather try to improve the process
During the six sigma project, data is collected about the outputs at various levels of the
input. When the data is analyzed, relationships can be established and even quantified
between the inputs and the outputs. Root cause and critical inputs can then be easily
identified and adjusted. As six sigma projects are usually complex in nature, therefore
they are usually expected to have high impact on the customer and/or business financials.
On simple problems when the root cause is already known, a six sigma project is not
actually needed but rather improvement and control efforts to solve the problem.
The Six Sigma DMAIC
The road map of any six sigma project consists of 5 main phases; Define, Measure,
Define Phase
This is the first phase in the life of a six sigma project. In this phase the problem is well
defined. Objective of the project is determined. Measures for the objective are put in
place. Time Schedule, Customer and Business Impact are also agreed upon during this
phase. Finally and most importantly the scope of the project has also to be defined, the
more limited the project scope is, the higher the probability of success. All the above
mentioned data is documented in the “Project Charter” that has to be signed and approved
Measure Phase
In the second phase of the project, all possible inputs of the process are identified. Data is
then collected about these inputs and their corresponding value of the process output.
This phase is usually one of the longest in the project. Two of the very important things
• Ensuring that all inputs are considered because if any of them is later discovered
very common that people gather wrong data due to personal, environmental or
equipment related factors. It is obvious that when the gathered data is not
In this phase the power of six sigma and statistics is really evident. During analysis
significant and non significant inputs are recognized. Relationship between significant
inputs and the output can be quantified using a regression model for example. Various
graphical and statistical tools are used in analysis. Graphical tools may include: Pareto,
Box plots, histograms, dot plots, scatter plots and many other tools. Statistical tools such
(ANOVA), paired T, Chi Square and many other tools may be relevant in this phase
Improve Phase
After the critical inputs have been identified in the Analyze phase, it should be now easy
to improve and adjust the process. The equation of the output as a function of the process
inputs that was established in the Analyze phase can now be used to identify the best
settings for the process input parameters that will ensure reaching the desired level of the
output.
Control Phase
The last phase of the project is the control phase. To maintain the results that have been
reached in the improve phase after extensive efforts through out the 3 or 6 months of the
project, control is extremely important. The control is applied on the process critical
inputs that were identified and fixed during the improve phase. Error proofing devices
and techniques could be used if applicable to sustain the new process settings.
Roles within six sigma organizations
In a typical six sigma organization , there exists Yellow Belts “YB”, Green Belts “GB”,
Black Belts “BB” and Champions. Yellow belts are the core team members in any six
sigma project. They are the ones who do most of the work in a project including data
collection and implementation of solutions when identified. Yellow belts are not exposed
to six sigma technical details as they attend only to a one day introductory course.
Green Belts are the team leaders of six sigma projects. They guide yellow belts
throughout the logical steps of the project. Green belts are the ones responsible for
days.
BB
BB
Theoretically, the presence of Green
essential for successful implementation. Black Belts and champions fulfill two forms of
vital support, which the project leader usually requires. These are technical and
managerial support respectively. Six Sigma Black Belts are very experienced technical
people who often aid green belts during their projects. Black Belts also provide technical
expertise required for project selection and evaluation. In addition to assisting green belts
and selecting projects, BB roles also include leading complex projects and training of
YB, GB and Champions. It is worth mentioning that the black belt is a six sigma full time
job.
The final important role in any six sigma organization is the role of the Champion.
Champions are non technical but rather senior people in an organization. Typically any
training course that describes their role and its importance in details. The roles of a
champion include adding the strategic dimension in evaluating potential six sigma
projects. Champion roles also include pushing Green Belts to progress quickly in their
projects and removing any possible road blocks in the project path. It has been proven
statistically that most of six sigma implementation trials that were unsuccessful, failed
because of technical incapability of black belts but much more often due to lack of
commitment”. It is a very strong and common reason for failure not only in implementing
Because six sigma improvement projects save a lot of money, they also require a lot of
time to get accomplished. A typical Six Sigma improvement project may last from 3 to 6
months which is considered quite long if compared to other improvement techniques such
as “Kaizen” 1. In some special cases a six sigma project may continue to be open for
more than one year. Occasionally, candidates may view their project as a boring and
endless task. In addition, six sigma projects also require a lot of effort and attention to
details. Persistent and committed leadership is therefore essential for the completion of
six sigma projects and consequently for the successful implementation of six sigma in the
entire organization.
S upport in the
Lack of S trong
w rong direction
M anagerial S upport
Lo
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F
ig
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an
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benefits
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Unsuccessful
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1. “Kaizen” is a Japanese word meaning: “Change is good”. It is a term that is used to describe small improvement projects that can be completed in 3 to 5 days
There are two main categories for the reasons why six sigma implementation may fail.
Technical factors may include the selection of the wrong projects and missing the better
ones. When a project with very low impact is selected, it gives a bad impression about six
sigma and what it can do. Same is true when a project with a very wide scope is selected,
probability of success of such project will be very low which again de-motivates people
and gives the wrong impression about six sigma. Some times, the implementation of six
sigma fails because of the technical incapability of the black or green belts but this case is
very rare
Management related factors are also very important; The main reason for failure of
really engaged, if they do not put in the effort of pushing and driving people to dig deeper
and deeper for improvement, the organization will remain stagnant. Managers have to be
convinced with what they can achieve using six sigma methodology and tools otherwise
they will not by driving it as they should. A good idea is that on the beginning of
implementation, limited scope or area of the organization is selected as a pilot run. When
the pilot succeeds it would be easier to convince other departments to go ahead and
implement.
Another important factor for successful implementation is having the correct measures in
place. Having six sigma Key Performance Indicators (KPIs) as well as targets for those
KPIs is necessary for implementation. KPIs may include; number of completed projects,
actual savings to date, customer complaints and others. In some organizations such as
General Electric, the bonus and promotion systems of the organization are directly linked
Last but not least, some times six sigma improvement efforts fail due to lack of
motivation. As mentioned earlier, six sigma projects need a lot of time and effort. They
also generate a good amount of savings to the companies. Savings of some projects may
savings to be spent on reward and recognition of concerned employees, other wise the
When six sigma was first introduced by Motorola it was used only in the manufacturing
field and more specifically to minimize defects. Below is an example of how the very
may exist, The Pareto helps us see quickly which ones are the most recurring.
100
30
80
Percent
Count
20 60
40
10
20
0 0
Type of Defect Color Leak Scratch Loose fit Dirt
Count 15 8 6 4 2
Percent 42.9 22.9 17.1 11.4 5.7
Cum % 42.9 65.7 82.9 94.3 100.0
In the chart above we could see that 43% of our defects are mainly color defects. Color
In this same example we can also see the Machines responsible for most of the defects as
shown below
100
30
80
Percent
Count
20 60
40
10
20
0 0
M/C No. M/C No. 2 M/C No. 5 M/C No. 9 M/C No. 1
Count 14 12 6 3
Percent 40.0 34.3 17.1 8.6
Cum % 40.0 74.3 91.4 100.0
Machine numbers 2 and 5 are the ones responsible for almost 75% of our defects.
More interesting than that, we can also see which M/C was responsible for which defect
0
M/C No. = M/C No. 5 M/C No. = M/C No. 9
16
12
0
C olor Leak S cratch Loose fit Dirt
Type of Defect
Now we have a much better and detailed view. Although we already knew that M/C
numbers 2 and 5 were responsible for 75% of our defects, we now understand what is the
exact problem with each M/C. We can conclude that M/C no. 2 has a lot of problems and
probably needs a full repair or replacement, whereas M/C no 5 has mainly a problem with
adjusting the color of the product. Attention has to be made however to whether it is an
certain product. Doing same exercise for several products may help identify the best
product / Machine mix. i.e which product to work on which M/C assuming we are having
several similar machines. In the chart below it is clear that for product A, machine
number 19 has the best productivity with a performance level higher than 90%
0.9 0.9
0.8
0.7
0.6
0.5
0.4
MC11 MC12 MC16 MC19 MC20 MC21
Machine
Other applications in manufacturing may involve evaluation of a substitute material for
example. In the chart below the average M/C speed is compared based on the material
type used. We can conclude that types C and F are two of the best options in terms of
machine speed.
100
90
80
Mean
70
60
50
A B C D E F
Material Type
Six sigma and statistical tools can still have more powerful and complex application like
in the following example. In this situation we are trying to model the tension of paper
coming out from a paper production machine based on the machine speed and
temperature. Graphical and statistical analysis are conducted for two types of paper
3D Scatterplot of Output: Paper tension vs M/C speed - RPM vs M/C Temp
Product
No.
A
B
100
90
O utput: P aper tension
80
70
280
260
345 240 M /C T emp
330
315 220
300
M /C speed - RP M
As can be seen from the above scatter plot, the paper tension increases with the increase
of speed or temp. We can also notice that product A (Shown in black) usually has higher
tension than product B (In red). Further analysis could be done using regression where
we can actually model the relation ship between the paper tension against temperature
and speed. Using a regression equation we can actually estimate the output paper tension
given the M/C settings. Making it even more useful, we can calculate the required M/C
Output: Paper tension = - 86.7 + 0.267 M/C speed - RPM + 0.322 M/C Temp
According to the available data, 88 % of the variation in paper tension is now explained
by the equation above or in other words by the variation in machine speed and temp.
Use of six sigma and statistics in Service Industries
Six sigma could be also used in service industries. Banks, hospitals, call centers and other
service industries make very good use of six sigma methodology and tools. In part 3 of
this document we will discuss in detail how the methodology was useful in solving a
Here we are going to discuss how small service providers like restaurants can make good
We are assuming a restaurant manger who is interested in the voice of the customer. He
is having complaints about his service level. Upon collecting some data, he was able to
see client satisfaction level as a function of the client waiting time to make an order
80
Customer satisfaction
60
40
20
0 5 10 15 20 25 30
Waiting time
Looking at the above graph, he could easily notice that satisfaction rating is heavily
model this waiting time as a function of the number of available staff members and the
30
20
Waiting time
10
8
0
6 No of Staff members
2
4 4
6
8
Time of the day
Looking at the graph and using the equation created through linear regression, he was
able to know how many staff members should be available in his restaurant at each hour
of the day so that the client waiting time would be equal to 10 minutes or less. He then
hired people on part time basis, so that even on the peak of deman he always had the
Marketing is of course one of the fields where statistics and six sigma tools could be used
the most. A simple example is illustrated here where a marketer is interested to see
whether customer preference for different car brands depends on the area where the
customer lives or not. She looks at the data of the cars sold during the last 3 months in
three areas: Giza, Maadi and Heliopolis. She is interested mainly in 3 brands: Audi,
10
Count
0
Dealer N ame (C ustomer) = M aadi Branch
30
20
10
0
Jeep Mercedes Audi
Brand
Looking at the chart above, she could easily see the dependence of product type on dealer
location. People living in Giza prefer to have a Mercedes where as those living in Maadi
prefer driving a Jeep. Heliopolis customers do not have a certain preference among the
three brands. The existence of the relationship between preferred product and area could
be proved using a Chi square test which has a wide use in the field of marketing
Chi Square Test: Dealer Name (Customer), Brand
Giza Branch 5 8 16 29
6.56 11.39 11.05 29.00
Heliopolis Branch 10 8 9 27
6.11 10.61 10.29 27.00
Maadi Branch 4 17 7 28
6.33 11.00 10.67 28.00
All 19 33 32 84
19.00 33.00 32.00 84.00
In this case the Chi square test was able to prove the existence of such relationship.
Similar marketing applications studying the effect of demographics such as gender, age
group, social class or others on product preference or packaging color and design for
example do exist.
Use of six sigma and statistics in Finance
Finance departments in any company are usually good sources for reliable data. The data
when analyzed however becomes much more useful. A simple example is a cost break
down using Pareto analysis. Pareto chart could be used for expenses break down can be
done for expenses by department or for the percent of budget compliance by department,
4000000 100
80
3000000
60
Percent
Cost
2000000
40
1000000
20
0 0
Country Morroco Algeria Sudan Egypt Ethopia Other
Cost 1205930 1184768 826791 615568 107003 107003
Percent 29.8 29.3 20.4 15.2 2.6 2.6
Cum % 29.8 59.1 79.5 94.7 97.4 100.0
the below example the finance manager is interested to know whether the delay is
80
70
Payment Duration (in Days)
60
50
40
30
20
Adawy Corporation Auto Maged El Masry & Sons
Dealer Name (Customer)
One-way ANOVA: Payment Duration (in Days) versus Dealer Name (Customer)
Source DF SS MS F P
Dealer Name (Customer) 2 1479 740 5.04 0.009
Error 69 10130 147
Total 71 11609
In this case, the ANOVA test was able to prove that the customer named “Adawy
Corporation” is paying in more time than the other two customers. Finance manager can
now focus his efforts on collecting payments from this particular customer on time.
Use of six sigma and statistics in HR
Graphs and statistical tests could be also used here to study the effect of post, age group
or years of experience on job satisfaction for example. In the below example the effect of
6
Mean Org Commitment
Female Male
GENDER
6
Mean Org Commitment
prove whether such difference exist or not. It is worth mentioning that especially in the
field of HR data source could be a questionnaire rather than observations like in the other
applications. This sometimes has its negative effect on the quality of data and
state of hope of employees. Two separate models are created for males and females in the
organization. When a strong relationship of this kind is noticed, HR could use the state of
hope of interviewees – provided they are able to assess it - as a predictor for their
3 4 5 6 7 8
Mean Dispositional Hope
Analysis of employee turn over is another famous application of six sigma tools in the
field of HR.
Statistics and Legal Judgments
Statistical tests are widely used in court in the western countries. Imagine a juice
manufacturer who states on his package that it contains 1 liter. Due to normal process
variation, quantity in each package may not be exactly equal to 1 liter. Some packages
may have 1.05 liters and others may have 9.9 for example. However, if the manufacturer
is honest, the over all average of 100 packages is expected to be very close to 1 Liter.
Assuming that the overall average turns out to be 0.96 liters, some people may claim that
the manufacturer is cheating whereas others may say no he is honest, its only sampling
errors. To prove whether the real average is below one litter or not, a hypothesis test has
to be made.
Test of mu = 1 vs not = 1
10.0
7.5
Frequency
5.0
2.5
0.0 _
X
Ho
_
X
Ho
In this example the t-test has proved that the true average of the population is somewhere
between 0.957 and 0.983 Litters with 95% confidence. In other words the true average
In this paper we have discussed how six sigma and statistics in general could be very
useful in various business fields. Examples from marketing, Finance, manufacturing and
human resources management were also discussed. A detailed case study from
telecommunication industry was presented in detail. It is important to note that all the
tools presented in this paper represent less than 25% of the tools that could be used in a
real six sigma project. Six sigma thinking methodology is also important not only the
tools. The concept of “Y = f (X)” is a very important one that people usually miss when
looking into their professional and their personal life problems as well.
how committed the leadership is. Their commitment depends usually on how convinced
they are with what a tool like six sigma can do for their business. Six sigma is of course
not the only way for improvement, but rather one among several useful ways.