Introduction

Question 1

What is the vision of 6-sigma?

Answer 1

Zero defects
3.4 DPMO

Question 2

What is the difference between Lean & 6-sigma?

Answer 2

Lean: waste reduction, flow faster, Toyota
6-sigma: reduce variation, reduce defects, Motorolla

Question 3

What is the structured approach for existing processes?

Answer 3

DMIAC

Question 4

What is the structured approach for new processes?

Answer 4

DMADV

Question 5

What does DMAIC stand for?

Answer 5

Define, measure, analyze, improve control

Question 6

What does DMADV stand for?

Answer 6

Define, measure, analyze, design, validate

Question 7

What question does the DEFINE phase answer?

Answer 7

What is the problem?

Question 8

What question does the MEASURE phase answer?

Answer 8

How big is the problem?

Question 9

What question does the ANALYZE phase answer?

Answer 9

What causes the problem?

Question 10

What question does the IMPROVE phase answer?

Answer 10

How to solve the problem?

Question 11

What question does the CONTROL phase answer?

Answer 11

How to ensure sustainability?

Question 12

Statistically what does 6-sigma mean (In % & DPMO)?

Answer 12

99.99966% or 3.4 DPMO

Question 13

When are gate reviews needed?

Answer 13

At the end of every DIMAC phase.

Question 14

What is required in a gate review?

Answer 14

Presentation of results; different for each phase of the DMAIC cycle

Question 15

Who is required to participate in gate reviews?

Answer 15

GB/BB, MBB, sponsor (mandatory)
team (optional)

Question 16

How long is a typical gate review?

Answer 16

~1 hour

Question 17

How long is a green belt project?

Answer 17

90-120 days

Question 18

What is the criteria for a 6-sigma DMAIC project?

Answer 18

Existing process
Existing pain
Unknown causes
Unknown solutions
Sponsor
Team
90-120 days

Question 19

Let’s discuss standard deviation. On a bell curve, what % equates to each sigma level?

Answer 19

1s = 68%
2s = 95% (z: 1.96 for sampling)
3s = 99.7%
6s = 99.99966

Question 20

Core processes need a minimum of what sigma?

Answer 20

+/- 3s

Question 21

Where does the pain for a six-sigma process come from? What is the name to help you remember?

Answer 21

Time, cost, and quality.
Business cares about time and cost.
Customer cares about quality.

OTOBOS - On time. On budget. On spec.