Six Sigma is a series of tools that are designed to improve processes and systems by reducing variations.  While it is unfortunately burdened with large amounts of technical jargon and some outright silly terminology, it can nevertheless be highly effective when the situation calls for it.  It can also be highly ineffective - and very time-consuming - if used where it doesn't belong.

Variation is the cause of many manufacturing woes.  Variation leads to inconsistency, which leads to defects, scrap, and rework.  Further, variation can lead to changes in performance, leading directly to field problems, service calls, general customer dissatisfaction and a perception of poor quality.

Six Sigma is intended to help remove as much variation as is practical (and necessary).  As the name implies, the ideal goal is to get a statistical defect rate of better than 3.4 defects per million units, or 99.99966% yield.  In statistical terms, this is termed a 'six sigma' process.

This level of quality improvement is achieved through rigorous and disciplined identification, measurement, analysis, and improvement of known causes of process variation.  Some of the analysis techniques are statistical, while others are specific to the situation at hand.  Variations might be from any of several causes, including changes in materials, people, and environment.

Six Sigma is a difficult (and potentially time-consuming) methodology, best applied to difficult problems.  Most problems don't need methods quite as involved as Six Sigma.  Fortunately, we also know a number of other problem-solving strategies that may be more applicable to your needs.

Six Sigma is also not a cure-all.  It is usually most effective when applied to relatively mature processes, because it is well suited towards finding and eliminating varitions that cause otherwise well-designed systems to misbehave.  It may also have some benefit when used against brand-new processes where the parameters and limitations are not yet well understood.

Our principal founder is a trained Six Sigma Black Belt with experience in applying Six Sigma techniques to difficult problems.  If you feel that Six Sigma might be of benefit to your situation, please contact us to discuss how we can help.