In today's rapidly globalizing world, the boundaries of the economy have started to disappear. Almost all companies are now trying to reduce costs on a global scale. At the same time, they are applying various methods to continue working customer-oriented and ensure customer satisfaction. Customers are satisfied when they receive high-quality products at the right price and at the right time. This ensures customer satisfaction. This is where Six Sigma comes into play. It is considered the most effective method that customer-focused businesses can use.
Six Sigma is a growth strategy used to increase business efficiency and profitability, meet customer satisfaction and expectations, reduce costs due to lack of quality, and maximize business efficiency. The definition of Six Sigma in a business is to increase satisfaction by working customer-oriented and, consequently, a cultural change that increases the profit margins and competitive advantage of the business.
Six Sigma is one of the leading methods used to make business processes more effective and efficient. Most people associate Six Sigma with production, but Six Sigma can be applied to any process in any industry. Today, almost every organization uses Six Sigma to establish a management system that systematically identifies defects and provides methods to eliminate them. Six Sigma is a method that provides organizations with the tools to enhance the capacity of business processes. This increase in performance and reduction in process variation leads to a decrease in errors and improvements in profit, employee morale, and product or service quality. Moreover, "Six Sigma quality" has become a term used to indicate that a process is well-controlled.

How is Six Sigma Calculated?

Six Sigma is a customer-focused improvement approach aimed at identifying and eliminating the causes of defects and errors in production and service processes, reducing costs and cycle times while increasing efficiency. In Six Sigma, the efficiency of processes is determined according to the sigma level. The calculation of a Sigma level is based on the number of defects per million opportunities (DPMO). Organizations can reveal the quality performance of their processes with just a few simple pieces of information:
● Number of units produced,
● Number of opportunities for defects per unit,
● Number of defects.
DPMO equals the number of defects multiplied by 1,000,000. This number is divided by the product of the number of opportunities for defects per unit and the number of units. After calculating the defects per million opportunities, you can use a conversion table or spreadsheet formula to convert DPMO to Sigma.

What is the Six Sigma Error Rate?

Sigma (σ) is a Greek letter representing the standard deviation of a population. The goal of the Six Sigma (6σ) method is to have a process with zero defects. A process that meets Six Sigma standards allows 3.4 errors per million opportunities. Reducing Sigma increases the number of errors produced by the process. Organizations that achieve Six Sigma performance have a significant quality and performance advantage over their competitors.

How is Six Sigma Applied?

There are various management approaches and different methods used to achieve improvements in a business. In fact, most of the improvement methods used are based on W. Edwards Deming’s “PDCA - Plan, Do, Check, Act” cycle. On the other hand, the Six Sigma method operates like a technician. It follows an approach similar to PDCA, known as DMAIC, derived from the first letters of the English words Define, Measure, Analyze, Improve, and Control.
Definition (Define)
The first step of the Six Sigma approach, known as DMAIC, aims to identify a potential problem and determine its impact on customer satisfaction, customers, stakeholders, employees, and profits. At this stage, fundamental customer requirements, project objectives and goals, team roles and responsibilities, process maps, performance criteria, etc., are defined. It also aims to define potential outputs and inputs of each process as well as the project's goals, constraints, and deadlines.
● Project management system and project planning,
● Project Indicators,
● Customer feedback,
● Detailed process diagram,
● Failure Mode Effects Analysis (FMEA)
● Cause and effect matrix.
Measurement (Measure)
In the measurement stage, project progress reports are completed, and deadlines and goals are defined. Then the project team is selected, and processes, suppliers, and customers’ representatives are included in this group. Inputs and outputs are defined as a process flowchart is drawn. A list of inputs and outputs of the problematic process is prepared, and relationships are checked using tools such as cause-and-effect diagrams, cause-and-effect matrices, and failure mode and effects analysis (FMEA). At this stage, the main goal is to ensure that project inputs and outputs are accurate and to illustrate the current state using various visual analyses. Efforts are made to check whether the accuracy of the process performance indicators is measured correctly. The adequacy of potential inputs and outputs is verified. After ensuring that a proper measurement system is in place, the adequacy of current inputs and outputs is determined.
Analysis (Analyze)
In the analysis stage, analyses are made to determine methods to eliminate the gap between the current performance of the problem or process and the desired goals. At this stage, statistical data analyses are used to help understand the data. Potential inputs that could affect outputs are analyzed using questions like where, when, and how. In this way, the order of importance, severity of the defect, etc. can be clarified.
Improvement (Improve)
In the improvement stage, solutions are generated that will eliminate problems in the process, and implementation plans are developed. Continuous improvement is achieved by involving necessary personnel in the improvement system through continuous training and motivation.
Control (Control)
It is not enough to achieve optimal conditions for the outputs; they must also be maintained. Verifying that critical inputs remain within selected conditions reduces the variability of outputs. In the control stage, if the improvement process is successful, it is verified, and the continuity of the improvement process over time is ensured. Actions to be taken include eliminating human errors, updating control procedures, providing current training, and ensuring the new process is under statistical process control by eliminating the specific causes of change. When the new process is stable, i.e., consistent, real business results are recorded and documented. If goals are not met, the DMAIC cycle is restarted as a corrective action.

What is the Six Sigma Level?

The Six Sigma certification is very similar to the certification system followed in martial arts, where a Six Sigma professional starts with a White Belt and progresses to Master Black Belt or receives an integrated certification offered by some institutes.
White Level / White Belt
● The White Belt is the simplest stage, open to any newcomer.
● People work with teams on problem-solving projects.
● The participant must understand the basic Six Sigma concepts.
Yellow Level / Yellow Belt
● The participant serves as a member of the project team.
● Reviews process improvements.
● Becomes familiar with various methodologies and DMAIC.
Green Level / Green Belt
This level of expertise brings more comprehensive criteria than the others. These can be listed as follows;
● At least three years of full-time employment.
● Understanding the tools and methodologies used for problem-solving.
● Practical experience involving projects that include a level of business transformation.
● Guiding Black Belt projects in data collection and analysis.
● Leading Green Belt projects or teams.
Black Level / Black Belt
This level includes:
● At least three years of full-time employment.
● Experience in a fundamental area of knowledge.
● Evidence of the completion of at least two Six Sigma projects.
● Demonstrating expertise in applying multivariable metrics in various business change settings.
● Leading different teams in problem-solving projects.
● Training and coaching project teams.
Master Black Level / Master Black Belt
The characteristics required to reach this level of expertise can be listed as follows;
● Holding a Black Belt certification.
● Having at least five years of full-time employment or proof of having completed at least ten Six Sigma projects.
● Having coached and trained Green and Black Belts.
● Having worked as a Six Sigma technology expert and in-house business transformation consultant for an organization.

How Did Six Sigma Emerge?

The Six Sigma approach began when the American company Motorola sold its Quasar television company to the Japanese company Matsushita due to the significant modifications made at the factory, which resulted in substantially reduced inefficiency and error rates. Curious about the secret of this Japanese success, Motorola experts determined that the situation was related to the quality of the process, and they started to struggle to improve Motorola's performance in the early 1980s. Motorola began to use Six Sigma techniques during in-house training with the hope of improving and developing the quality of mobile phones. With this method, Motorola was able to measure its shortcomings across all business lines and, in 1988, became the first company to receive the Malcolm Baldridge National Quality Award after achieving all of its goals using the Six Sigma methodology. By the end of 1995, General Electric began to implement Six Sigma across the organization with all leadership and support systems. In 1997, the company spent a total of $400 million on all Six Sigma-related training and generated $600 million in revenue through the implementation of Six Sigma. After Motorola and General Electric, another company to apply the Six Sigma approach was IBM. IBM also achieved significant success with the Six Sigma approach. Subsequently, the Six Sigma method gained popularity in the automotive industry and has since become applicable in almost every field today.

What Are the Benefits of Six Sigma?

In today's constantly evolving and changing markets, the most important way to keep up is by innovating and adapting to the ever-changing conditions. Six Sigma creates the culture and capability that businesses need to rediscover themselves in a continually changing environment. The benefits of Six Sigma include: ● Increases customer satisfaction,
● Reduces product costs,
● Increases market share,
● Provides cultural development,
● Increases efficiency,
● Reduces the error rate,
● Offers service improvement opportunities,
● Increases product quality,
● Delivers high performance,
● Ensures continuous success,
● Enhances learning speed,
● Facilitates speaking a common language,
● Provides performance targets for employees,
● Increases value for customers,
● Accelerates improvement and growth.

Six Sigma Stages

Six Sigma is a process used to improve the quality of products and services. It is a data-driven method that uses statistical tools and techniques to reduce defects and increase customer satisfaction. The Six Sigma process has six stages. These are; Define, Measure, Analyze, Improve, Control (DMAIC) and Design, Measure, Analyze, Design, Verify (DMADV).

The Definition stage is the first step of the Six Sigma process. It involves determining project objectives and goals, collecting customer requirements, and defining the scope of the project. The Measurement stage involves collecting data and measurements to understand the current process. In the Analysis stage, data is analyzed to determine the root cause of the problem. The Improvement stage includes finding solutions to the problems in the processes and implementing new technologies. The Control stage involves monitoring the process to ensure the sustainability of the improvements.

The DMADV process is used when creating a new product or service. It involves defining project objectives and goals, measuring customer requirements, analyzing potential solutions, designing the details of the process, and verifying the results. The Design stage involves creating a plan for the process and setting objectives. The Measurement stage involves testing the process against the objectives. In the Analysis stage, the process is evaluated to identify areas for improvement. The Design stage includes making changes to the process to improve its performance. Finally, the Verification stage includes testing the process to ensure that the changes are effective.

Six Sigma is a powerful tool for business transformation. It offers a structured approach to improve the quality of products and services and ensure customer satisfaction. By following the six stages of the Six Sigma process, organizations can enhance their performance, reduce costs, and increase customer satisfaction.

Six Sigma Belts

There have been three different generations of Six Sigma: the First Generation, which focused on reducing defects, covering the period from around 1987 to 1994; the Second Generation, which focused on process improvement, spanning from around 1994 to 2004; and the Third Generation, which focuses on innovation and customer value, starting in 2004 and continuing to the present day.

The First Generation of Six Sigma focuses on reducing defects in manufacturing processes and developing systems to identify and address the root causes. This generation primarily relies on statistical methods and tools such as process mapping, SIPOC analysis, and FMEA.

The Second Generation of Six Sigma shifts its focus from defect reduction to process improvement. This generation introduces the use of Lean tools and techniques such as value stream mapping and Kanban cards. It also emphasizes the use of project management techniques like setting smart goals and working in teams.

The Third Generation of Six Sigma focuses on innovation and customer value. This generation introduces tools such as Design of Experiments, design thinking, and agile project management. It also emphasizes the importance of data-driven decision-making and customer-centric design.

Overall, the evolution of Six Sigma has brought an increased focus on customer value and innovation. As organizations adopt the latest generation of Six Sigma, they can use the best tools and techniques to drive continuous improvement and deliver the best possible customer experience.

The Six Sigma Process of Business Transformation

DIGITAL TRANSFORMATION has become the hottest buzzword of this decade. New technologies and tools have accelerated the journey of large and small businesses competing for a larger slice of the business pie in a fast-paced competitive environment. Yet, is that enough to smooth out a company’s operations? Can an independent technology application eliminate a bottleneck in a production process or support the resolution of service design defects? While digital transformation may accelerate a company’s management, it must be equally supported by quality control and business execution methods.

The Six Sigma operating scope contains a simple goal. It aims for optimal customer satisfaction by delivering near-perfect goods and services. It is achieved through a two-pronged approach. The first step involves understanding that it does not drive demand and sales or loyalty. The second step entails mapping out the behaviors in a specific process to eliminate non-value-adding operations and gathering data to identify waste areas.

To successfully execute a Six Sigma project, it is crucial to include all components, adopt a process for problem-solving, and foster a culture of response and accountability towards changes in management. It is also essential to have a team that is proficient in the principles and concepts used. In this way, special training and knowledge can be effectively imparted.

There are two main Six Sigma meetings: DMAIC and DMADV. DMAIC is a data-driven approach used to leverage existing products or services for better customer satisfaction. It is an acronym for the five phases: Define, Measure, Analyze, Improve, and Control. DMADV is a part of Design for Six Sigma used for designing or redesigning different products and services.

Six Sigma can have a significant impact on an organization, improve performance and sustain its processes, thus observing defect rates, boosting employee morale, and elevating products or services, all while achieving a higher level of profitability. With the right team and adequate training, businesses can utilize Six Sigma as a powerful tool to drive improvements.

How is Success Achieved in Six Sigma?

Six Sigma is a business strategy used to enhance profitability by identifying and eliminating defects in processes. It employs a data-driven, rigorous approach focused on process improvement, customer satisfaction, and cost savings. The approach consists of five stages (Define, Measure, Analyze, Improve, and Control) and is used to determine and eliminate the root causes of defects.

Success in Six Sigma is achieved through a structured process and focus on quality. This requires a comprehensive understanding of the problem and its root causes, in addition to an effective data collection and analysis process. The Define stage is used to identify the problem, its root causes, and the needs of customers. The Measure stage is used to collect data, analyze data, and set targets. The Analyze stage is used to determine the root causes of the problem and identify potential solutions. The Improve stage is used to design and implement the solutions, and the Control stage is used to measure and track the success of the solutions.

Success in Six Sigma also requires an effective team. The team should consist of individuals with various skills, including data analysis, problem-solving, and process improvement. Each team member should be knowledgeable and experienced in their area of expertise. The team should also include a Six Sigma certified Black Belt or Master Black Belt, who is responsible for overseeing the project.

Finally, success in Six Sigma requires the commitment of all stakeholders, including top management. This commitment should include setting realistic goals and expectations, providing necessary resources such as data and personnel, and offering continuous support and guidance throughout the project.

By following the Six Sigma process and involving all stakeholders, organizations can achieve success in their Six Sigma initiatives. The approach will help organizations identify and eliminate defects, improve customer satisfaction, and achieve cost savings.

What is the Secret to Six Sigma’s Success?

Six Sigma is one of the most successful business processes in the world. It is a data-driven approach to quality management that focuses on reducing defects, increasing customer satisfaction, and lowering costs. The success of Six Sigma is attributed to its structured approach, the use of data and analytics, and the commitment of all stakeholders. The first key to the success of Six Sigma is its structured approach. It follows a five-step methodology that includes Define, Measure, Analyze, Improve, and Control (DMAIC). This approach focuses on identifying and addressing the root causes of defects in a process rather than just the symptoms. It also emphasizes the importance of data-driven decision-making and customer-focused design.

The second key to Six Sigma’s success is the use of data and analytics. Six Sigma focuses on collecting and analyzing data to identify areas for improvement. This data-driven approach allows decisions to be made based on facts rather than opinions. This reduces the risk of new processes being implemented without data support. The third key to Six Sigma’s success is the commitment of all stakeholders. All stakeholders, from top management to experts responsible for implementing the process, should be involved in the process. This commitment provides the necessary resources and guidance to ensure the success of the process.

Finally, the Six Sigma process should be supported by the right people. A team of experts is required to ensure the proper implementation of the Six Sigma process. This team should consist of individuals with various skills, including data analysis, problem-solving, process improvement, and Agile project management.

What makes Six Sigma successful is the combination of these four fundamental elements. Organizations can reduce defects, improve customer satisfaction, and achieve cost savings by following the Six Sigma process.