International Journal of Science and Research (IJSR)

ISSN (Online): 2319-7064

Impact Factor (2012): 3.358

A Review of Six Sigma Approach: Methodology,

Implementation and Future Research
Meena Ahirwar1, Dr. Devendra Verma2
1
Student, Institute of Engineering and Technology DAVV
Devi Ahilya Vishwavidyalaya, Institute of Engineering & Technology, Indore, MP, India
2
Lecturer, Institute of Engineering and Technology DAVV
Devi Ahilya Vishwavidyalaya, Institute of Engineering & Technology, Indore, MP, India

Abstract: Six Sigma is an approach that improves quality by analyzing data with statistics. In recent years there has been a significant
increase in the use and development of the Six Sigma methodology in manufacturing industry and others. It is high time to have a
review on the Six Sigma approach. This paper reviews some related literatures to describe methodology, implementation and future
researches. The present paper summaries four issues within the sub-category of the initial Six Sigma concepts: basic concept, DMAIC,
DFSS and deployment. Then, some sectors that benefit from the implementation of Six Sigma are listed out, and the key factors
influencing the successful Six Sigma project implementation are identified. At last, some topics for future research are presented.

Keywords: Six Sigma, methodology, implementation, future Research quality management

1. Introduction in the 1980s, many companies including GE, Honeywell,

Sony, Caterpillar, and Johnson Controls have adopted Six
Statistically, Six Sigma refers to a process in which the range Sigma and obtained substantial benefits. Six Sigma is a long-
between the mean of a process quality measurement and the term commitment. It won’t work well without full
nearest specification limit is at least six times the standard commitment from upper management. Six Sigma changes
deviation of the process, shown as Fig. 1 and Fig. 2. the way a company thinks by teaching fact-based decision
making to all levels. In recent years, interest from the
academic community has increased dramatically. However,
to date only few papers can be identified as a literature
review regarding Six Sigma focusing on the basic concept,
implementation and future of Six Sigma [1-3]. Therefore, it
is the high time to have an extensive review on the related
literatures. The present paper syntheses four issues within
Six Sigma basic concepts. It aims to identify the key factors
influencing the successful implementation of Six Sigma
projects. Finally, the areas of future research are
summarized.
Figure 1: Illustration of centered 3 Sigma
2.Methodology of Six Sigma
Six Sigma has been defined as the statistical unit of
measurement, a Sigma that measures the capability of the
process to achieve a defect free performance. Six Sigma has
the ability to produce products and services with only 3.4
defects per million, which is a world-class performance. Six
Sigma has also been described as a high performance data
driven approach in analyzing the root causes of business
problems and solving them.
Figure 2: Illustration of Six Sigma process
A. Basic Concept
The traditional quality management approaches, including
Statistical Quality Control (SQC), Zero Defects and Total
Conceptual papers also consider the overall concept,
Quality Management (TQM), have been key players for
attempting to analyze the development of Six Sigma and
many years, while Six Sigma is one of the more recent
explain its statistical foundation. Bothe presents a
quality improvement initiatives to gain popularity and
statistically based reason for adding a 1.5 Sigma shift before
acceptance in many industries across the globe. Six Sigma
estimating process capability, proposing a new capability
differs from other quality programs in its top-down drive in
index, called dynamic Cpk [5]. He also suggests future study
its rigorous methodology that demands detailed analysis,
on the impact and behavior of the shift in various
fact-based decisions, and a control plan to ensure ongoing
circumstances. Antony studies the strengths and the
quality control of a process. Since its initiation at Motorola
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Paper ID: 02014420 2129
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 International Journal of Science and Research (IJSR)
ISSN (Online): 2319-7064
Impact Factor (2012): 3.358
weaknesses of Six Sigma in detail and links Six Sigma to Improve Improve the process to eliminate variations
statistical thinking [6]. He suggests that Six Sigma has a Develop creative alternatives and implement enhanced
strong statistical foundation and consequently is likely to plan
continue to be of importance in the future. Table I Control Control process variations to meet customer requirements
Develop a strategy to monitor and control the improved
summarizes Six Sigma business strategies, tools, techniques,
process
and principles Implement the improvements of systems and structures

Table 1: Strategies, Tools, Techniques And Principles [1]

C. DFSS Process
Strategies and Principles Tools and Techniques
Project management Statistical process control
Data-based decision making Process capability analysis Design for Six Sigma (DFSS) is a systematic methodology
Knowledge discovery Measurement system analysis utilizing tools, training and measurements to enable the
Process control planning Design of experiments organization to design products and processes that meet
Data collection tool & technique Robust design customer expectations and can be produced at Six Sigma
Variability reduction Quality function deployment quality levels [11].
Belt system Failure mode and effects analysis
DMAIC process Regression analysis
Change management tools Analysis of means and variances
Hypothesis testing
Root cause analysis
Process mapping

B. DMAIC Process

DMAIC is a closed-loop process that eliminates

unproductive steps, often focuses on new measurements, and
applies technology for continuous improvement. Some
papers focus on explaining the DMAIC contents, with some
authors discussing each phase of DMAIC in detail [7]. For
example, raises teals .present self-learning training material
for DMAIC, using a fictitious application [8]. This paper
helps the readers to learn how to carry out a small-scale Six
Sigma project, including guidance on the application of
tools. It indicates a perceived need for training material and
suggests that an avenue for further research is to develop
training material to cover a wider range of applications and DFSS is potentially far more effective than DMAIC as its
larger scale projects. Other papers concentrate on specific application is in the early stage of new product/process
aspects of DMAIC, such as the project selection process in development, thus the papers under this category aim to
the Define phase or process control in the Control phase, provide an explanation of DFSS and why it is different from
explaining some key measures in Six Sigma, such as project DMAIC [12-15]. For example, Madera explains the DFSS
metrics and Roll Throughput Yield (RTY). For example, methodology, its key aspects and how it enhances the design
Sneer emphasizes the importance of the project selection process; improving New Product Development
process in the Define phase for the successful (NPD).Antony presents DFSS using the Identify, Design,
implementation while Mason suggests using multivariate Optimize and Validate (IDOV) approach. Treichler et al.
statistical process control in the Control phase [9-10]. These discusses the use of DFSS in the design function of major
papers tend to explain the features of DMAIC rather than US corporations and Koch et al. explain DFSS in detail,
critically appraising or enhancing it. Future research should using as an example the application of DFSS in automotive
investigate whether aspects of DMAIC need to be modified crashworthiness under an engineering design context. All of
to increase its scope, for example for the service sector or these studies of DFSS have been undertaken in a
non-profit organizations. If so, research to enhance the manufacturing context. Hence, there is a need for more
methodology may then be needed. Table II presents the key extensive study to consider new areas of DFSS application,
steps of Six Sigma using DMAIC process. such as how DFSS can be applied to nonmanufacturing
processes.
Table 2: Key Steps of DMAIC Process
Steps Key processes
D. Six Sigma Deployment
Define Define the requirements and expectations of the customer
Define the project boundaries
Define the process by mapping the business flow Papers addressing Six Sigma deployment focus on people
Measure Measure the process to satisfy customer’s needs issues, with particular emphasis on the professional role of
Develop a data collection plan Belts and training issues. For example, some authors
Collect and compare data to determine issues and shortfalls describe the role of BBs and the required qualifications
Analyze Analyze the causes of defects and sources of variation including the suggestion of a BB training curriculum. Hoerl
Determine the variations in the process et al. suggest that it is a positive career move for a
Prioritize opportunities for future improvement statistician to take up a leadership role in Six Sigma,
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Paper ID: 02014420 2130
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 International Journal of Science and Research (IJSR)
ISSN (Online): 2319-7064
Impact Factor (2012): 3.358
implying that it is important for BB to have statistical skills adopted, with the majority of papers studying
[16]. However, care is needed in selecting the right qualities implementation issues in USA. Six Sigma principles and
for Belts, as it is important for Six Sigma to retain an the healthcare sector are very well matched because of
inclusive stance rather than becoming too closely aligned the healthcare nature of zero tolerance for mistakes and
with specialist skills. Calcutta suggests the use of Myers- potential for reducing medical errors. Some papers
Briggs Type Indicator (MBTI) tool to assist BBs to work explain how Six Sigma improves healthcare service
effectively with others [17]. It is claimed that this tool helps quality by reducing medical errors and increasing patient
BBs to understand the personality types of team members safety.
and communicate more effectively, gain cooperation and b) Financial services sector
overcome resistance. However, these papers are descriptive In recent years, finance and credit department are
using authors' experience. Therefore further research is pressured to reduce cash collection cycle time and
needed to investigate the qualities required by the Belt variation in collection performance to remain
candidates. Further rigorous research is needed to investigate competitive. Typical Six Sigma projects in financial
evidence for the effectiveness of the proposed training institutions include improving accuracy of allocation of
methods. Another issue regarding deployment is the cash to reduce bank charges, automatic payments,
successful use of teams, given that Six Sigma projects are improving accuracy of reporting, reducing documentary
accomplished through team efforts. It is important to focus credits defects, reducing check collection defects, and
on team success, rather than individual success, if Six Sigma reducing variation in collector performance [19]. Bank of
projects are to be successful overall. No paper has been America is one of the pioneers in adopting and
identified that address an individual's reaction or resistance implementing Six Sigma concepts to streamline
to Six Sigma. Management involvement and support are operations, attract and retain customers, and create
essential to Six Sigma deployment, as is the case for many competitiveness over credit unions. It has hundreds of
other initiatives. Haikonen et al. present a preliminary case Six Sigma projects in areas of cross-selling, deposits, and
study on the role of management in the improvement of the problem resolution. Bank of America reported a 10.4%
deployment process in Six Sigma and highlights its key increase in customer satisfaction and 24% decrease in
finding that the level of management support is positively customer problems after implementing Six Sigma [20].
related to how well they understand the Six Sigma c) Other Sectors
methodology [18]. Still, there are other sectors in Six Sigma implementation,
including Civil Engineering and Construction, Research
3. Six Sigma Implementation and Development, Supply Chain Management, Human
Resource Management and Train and safety.
Six Sigma implementation can be divided into types of
business: manufacturing and non-manufacturing, described C. Success factors in Six Sigma implementation
as follows.
Some papers present the key ingredients for the effective
A. Manufacturing business introduction and Six Sigma implementation in
manufacturing and services organizations as the following
Cases of successful companies that have adopted Six Sigma [21-22].
are presented in many papers. The authors describe how the
respective companies’ implement Six Sigma, giving insights 1) Management commitment and involvement.
into issues of perceived best practices. Motorola was the first 2) Understanding of Six Sigma methodology, tools, and
organization to use the term Six Sigma in the 1980s as part techniques.
of its quality performance measurement and improvement 3) Linking Six Sigma to business strategy.
program. Six Sigma has been successfully applied in other 4) Linking Six Sigma to customers.
manufacturing organizations such as Boeing, DuPont, Ford 5) Project selection, reviews and tracking.
Motor, Seagate, Texas Instruments, GE, etc. All of these 6) Organizational infrastructure.
papers are categorized as descriptive papers, giving details of 7) Cultural change.
business cases, but without a rigorous case study approach. 8) Project management skills.
As a result of Six Sigma being initiated in the USA, all the 9) Liking Six Sigma to suppliers.
above success stones describe US companies. Very few 10)Training.
papers have been found regarding successful implementation
strategies for whole businesses in other parts of the world. 4.Future Research of Six Sigma and Conclusion
Therefore, academic research outside USA could be a good
area of future study to determine any comparative Given that Six Sigma methodology has been around in
differences in implementation issues, such as those caused industry for over a decade, it now seems unimportant to
by cultural issues. determine whether Six Sigma is better than other
approaches. It is more important to learn how to enhance the
B. Non-manufacturing business Six Sigma methodology and improve implementation issues
for the growing number of firms that are choosing to adopt it
a) Healthcare sector as a means of process improvement. The primary focus
Healthcare services are one of the major active should be on improving overall management performance,
nonmanufacturing contexts in which Six Sigma has been not just pinpointing and counting defects. Researchers and
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 International Journal of Science and Research (IJSR)
ISSN (Online): 2319-7064
Impact Factor (2012): 3.358
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