SIX SIGMA

MANAGEMENT AND
LEAN TOOLS
❖ What is Six Sigma
❖ Organizing Lean-Six Sigma
❖ Application Six Sigma and Lean Tools in Halal Industry
 SIX-SIGMA
❖ Approach to improving quality
❖ Differentiate it form traditional continuous improvement:
a) represent a well-thought-out-packaging of quality tools and philosophies in
an honest effort to provide rigor and repeatability to quality improvement
efforts.
b) much more cost-reduction-oriented than traditional continuous
improvement
c) way it is organized
d) Six Sigma and lean production have been combined into an approach
termed “Lean-Six Sigma. Emphasis on reducing waste.
 What is Six Sigma?
⮚ refer to Greek symbol , which designates a
standard deviations from a specification limit to
the mean of a highly capable process.
⮚ began at Motorola in 1982, that costs be cut in half.
⮚ an advanced quality improvement approach
designed to help tackle the most difficult quality
problems.
⮚ It involves planning, organization, training, human
resources planning, and pay for knowledge.
⮚ requires both organizational and individual
cooperation to achieve a goal.
 Organizing Lean-Six Sigma
- Key Players in Six Sigma efforts:

❖ Champion
✔ work with black belts and potential black belts to identify possible projects.
✔ get information from a variety of sources such as the voice of the customer (VOC), the
voice of the business (VOB), the voice of the employee (VOE).
✔ Six sigma is not so much about tools; it is about managing the process for
improvement.
✔ Provides continuing support for the project and validates the results at the end of the
project.
✔ Small company = CEO, larger company= senior executives.
❖ Master black belts
✔ Serve as mentors and trainers for new black belts.
✔ Training in-house and can reduce costs.

❖ Black belt
✔ Key to lean-Six Sigma
✔ Trained individuals who train for about four months untill these individuals are committed full
time to completing cost-reduction projects.

❖ Green belts
✔ Basic quality tools and work in teams to improve quality.
✔ Assigned part-time to work on process and design improvement.
✔ Small company= 1 black belt & 60 green belts.

❖ Yellow belts
✔ employees familiar with improvement processes.
 Packaging Lean with Six Sigma

1. When firm undertook implementing Six Sigma, many saw it had a lot of
things in common with lean manufacturing.
2. Two competing models for improvement, six sigma and lean =lean-Six
Sigma.
3. Six sigma =more oriented toward reducing wastefulness in
organizations.
4. Follow DMAIC process.

DMAIC
❖ Developing the Business Case
1) Identifying a group of possible projects
efine
2) Writing the business case
D
3) Stratifying the business case into problem statement and objective statements.

✔ Short statement outlining the objectives, measurables, and justification for the
project.
❖ Project evaluation
✔ Project risk assessment
❖ Pareto Analysis
✔ Is to perform a cost of poor quality (COPQ) analysis.
✔ Internal and external failure costs will help determine where the most benefit can be
found
❖ Project Definition
✔ Consist problem statement, project goals/objectives, primary metrics, team
member identification.
 easure
M
❖ Selecting process outcomes
✔ Understand the process, involves prosses mapping.
✔ Process map is a flowchart with responsibility.

❖ Verifying Measurements
✔ Measurement system analysis (MSA) is used to determine and
precision of the measurements.
✔ problems in measurement can be result for a variety of reasons:
1)the measurement gauges are faulty
2)operators are using gauges improperly
3)training in measurement procedures are lacking
4)the gauge is calibrated incorrectly
❖ Define your performance objectives
❖ Identify independent variables
nalyze
❖ Analyze sources of variability.
A
Phase
mprove Phase
❖ Process involves offline experimentation.
I

ontrol
C
❖ involves managing the improved processes using process charts and
implementing control plans.
Phase
 Design For Six Sigma (DFSS)
❖ Used for designing new products and services with high performance,
as measured by customer-based, critical to quality metrics.
❖ Process : DMADV process
Design Measure Analyze Design Verify

❖Method : IDOV (focused on final engineering design optimization)

Identify Design OptimizeVerify
Lean Six Sigma from a Contingency Perspective
❖ Lack of leadership by champions.
❖ Misunderstanding roles and responsibilities.
❖ Lack of appropriate culture for improvements.
❖ Resistance to change and the Six Sigma structures.
❖ Faulty strategies for deployment.
❖ Lack of data.
 Application Six Sigma and Lean Tools in Halal
Industry

HCTQ= halal critical to quality

HCP= Halal Critical Points SS=
six sigma

Reference : Vanany, I., Tan, K. H., Siswanto, N., Arvitrida, N. I., & Pahlawan, F. M. (2020). Halal six sigma framework for defects reduction. Journal of Islamic Marketing.