GE Medical Systems

Information Technologies

Applying Six Sigma

Tools to Everyday
Projects
Erin Beal Welch
Lori Beard
Jennifer Fleming

Objectives and What We’re Doing Today

Objectives
• Describe Six Sigma
• Discuss tools used in Six Sigma
• Use at least one tool within a Six Sigma project
• Describe how to use the tool in the scope of your job

What we’re doing

• High-level overview of Six sigma
• Identify the tools
• Group work with the tools
• Report-Out about what your group did

Lots to cover and little time!

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Six Sigma Overview

What is Six Sigma?
• Methodology, metrics (3.4 dpmo!), philosophy
• Statistical analysis
• Improved processes = Increased performance + decreased variation
• Profits, morale, quality
• Tools

What is a Six Sigma GREEN BELT?

Six Sigma~The Way We Work

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1
What Are the Tools?
• Brainstorming
• Affinity Method
• Fishbone (Cause and Effect Diagram)
• Process Map
• Quality Function Deployment (QFD)
• Failure Mode Effects Analysis (FMEA)
• Scorecard
• Survey
• Pugh Matrix (Criteria matrix)

Tools You Can Use

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Samples of the Tools: Brainstorming

•Creative solutions to a
problem—radical!
•Ideas: odd, broad and
FAST!
•A NEW way of looking at
the problem
•No judgment or analysis at
this point
•May later lead to Affinity
Diagramming (next slide)

Well-defined problem = successful brainstorming

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Samples of the Tools: Affinity Method

Affinity Diagramming allows you to sort a brainstormed list,
moving ideas from the brainstorm into affinity sets, and creating
groups of related ideas.
•Use to refine brainstorming output.
•Grouping ideas. Use to organize facts or ideas.
•Sometimes called: KJ Method (after author Kawakita Jiro)

When using the Affinity Method:

•Not important to define WHY ideas belong together.
•You may put an idea in more than one set if appropriate.
•Do small sets need to be part of the larger group?
•Do larger groups need to be broken down?
•After grouping ideas, then title the groups.

Organize your brainstormed list

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2
Samples of the Tools: Fishbone
Identify potential issues or problem causes in an orderly
manner
Ask “Why?”

Summarize major
factors—
consider:
• Methods,
Machines,
Materials, People
• Places,
Procedures,
People, Policies,
• Surroundings,
Suppliers, System,
Skills

“Cause and Effect Diagram”

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Samples of the Tools: Process Map

Flowchart/flow
diagram
How it works vs. Manuals
Manuals Manuals are
Manuals
ordered by
how it should released
prepared &
sent to printer
processed at
the printer
Manufact-
uring
work
Agreement on
how it works
Manuals are
Manuals Manuals
packaged
Basis for received from
printer
and sent to
received by
customer
examining areas customer

for improvement

Activity: Process map how to make lasagna?

Well-defined problem = successful brainstorming

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Samples of the Tools: QFD & Pareto Chart

Used for:
•Ranking by
importance and
frequency
•Prioritizing
•Analyzing
groupings of data
•Analyzing the
impact of process
changes

Also called a Criteria Matrix

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3
Samples of the Tools: FMEA
Explore contingencies and determine risk.
Determine consequences of failure.
Plan for the unexpected!

Failure Mode Analysis or Risk Assessment or Process Decision

Program Chart (PDPC)
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Samples of the Tools: Scorecard

A scorecard is an evaluation device that
specifies the criteria your customers will use to
rate your business's performance in satisfying
their requirements.

Scorecards make management happy

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Samples of the Tools: Survey

•Surveys can range anywhere from full-blown assays of an
entire population to informal 5-question emails to a few people
in the office. It all depends on the information you are looking
for.
•Sometimes called focus groups. Focus groups are smaller and
usually meet in an informal, discussion type meeting.
•Surveys are more formal and are usually sent to a larger
population.
•Survey questions should be open-ended and not steered
toward the answer you want.
•Rephrasing the question different ways can be helpful.
•Make sure questions are clear—have someone review the
questions before you send it out.

Surveys need to be well formed and unbiased to get good data

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4
Samples of the Tools: Pugh Matrix

•Determine
which solutions
are more
viable than
others
•Build
consensus
among the
team
•Scoring tool

Also know as “Criteria-based matrix”

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Other Tools Available

Other tools available that we won’t be using today:
• Histogram Chart
• Scatterplot Chart
• Statistical tools (Analysis of Variance [ANOVA], Chi-
Square, etc)
• Gage R&R
• Benchmarking
• Regression Analysis
• And on, and on, and on…

Other Tools You Can Use

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Using the Tools: Brainstorming

Brainstorming Rules:
• ANY answer is a good answer
• Quantity over quality
• Set a target number of answers to generate

Brainstorm for 3 minutes at each table to come up with at

least 30 ways to use a rake handle. Have one person
take notes. We will let you know when it is time.

Really, this will be painless. ☺

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5
Using the Tools: Groupwork
The main portion of the workshop will be spent in groups
using the tools presented.

Your assignment:
• Each table will be assigned one or more tool(s) and a
case study with which to use the tool.
• Work through the case study.
• Discuss ways to use the tool outside of the scenario,
analyze its overall effectiveness
• Prepare a 2-3 minute presentation (complete with
transparency) on the tool and their findings.

Really, this will be painless. ☺

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Reporting Out

• Use the transparency provided to generate a 2-3 minute

presentation on the tool your group used.
• Think of other applications of the tool to your everyday
work.
• Select a representative for your group to present your
findings and talk to the transparency

No you don’t have to stand at the front of the room

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Great Resources
On the web
•http://www.isixsigma.com/
•http://www.isssp.com/
•http://www.sixsigmaforum.com/

In the bookstore
•The Power Of Design for Six Sigma (079316060X)
•The Six Sigma Way Team Fieldbook: An Implementation Guide for
Process Improvement Teams (0071373144)
•The Six Sigma Handbook (0071372334)

Thank you for your attention and participation! Good luck!

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