Integrating Six Sigma in a Manufacturing Process - Case Study Example

The small organizations might find it difficult to implement the Six Sigma methodology due to their limited resources. There are also an additional set of difficulties that will make their implementation different from that of the large organizations. The study deployed the case study research design. The data collection method for the study was mainly secondary and secondary data analysis method was used. There were three research questions: What is the suitable method to which Six Sigma can be integrated into the manufacturing process?

How can Six Sigma be deployed in Constraints Management for the improvement of the manufacturing process? What are the limited resources constraints for the integration of Six Sigma in the manufacturing companies? The results showed that there are several companies that have managed to integrate Lean and Six Sigma since the two go hand-in-hands. Some of the companies include Sony, Kodak, General Electric, and Motorola Solutions. However, for the study, the focus was on Aramco- Saudi Arabia; Sabic-Saudi Arabia; Holden Limited Australia; Coca-Cola Amatil International; Amazon International; Ford Motor Company; Boeing Company; and General Electric.

The analysis of the companies indicates that Six Sigma is important in the development of a company. It does not only increase the companies’ profit but also can be used to address environmental concerns linked to businesses. Six Sigma is simply a measurement technique that aims to make the quality of products and services to be better. It is a data-driven methodology and approach that aims at eliminating the defects in the industrial processes from transactional to manufacturing and from services to products.

Six Sigma can also be defined as a quality program that aims to improve the experience of the customers, builds leaders that are better and lowers the business cost. Six Sigma uses statistical tools to fight the variability that a company may be experiencing. All companies usually experience variation thus making Six Sigma critical. It allows the reduction of the variability in the company to the lowest state possible. Most of the project teams have models that assist in the integration of the Six Sigma.

The models are in form of manuals or guides that help resolve a problem in a company based on variation. 

According to Gitlow and Levine (2005), the most common strategy or model that the project teams use is the Define, Measure, Analyse, Improve, and Control abbreviated as DMAIC. The methods is based on a guideline that enables the project team to know when and what statistical tools to use. It also enables the statistical and other tools used in a manufacturing company to understand the project priorities as per the effect and variation associated with the processes. 1.2 Implementing Six Sigma in Organizations At the organizational level, Six Sigma simply means a precise way to measure quality.

In other words, it is a precise method to which quality in an organization can be measured. Six Sigma is usually a methodology used to eliminate defects and it is a data-driven approach (Six Sigma 2017). The process is disciplined hence eliminating the defects in all the processes. It helps in the driving the process towards the six standard deviations between the nearest limit specified and the mean in all the processes. In explanation, it aims to perfect the processes from service to product and transactional to manufacturing.

Statistically, Six Sigma describes the performance of a process quantitatively. To achieve Six Sigma in any given process, the process must give more than 3.4 defects for every a million opportunities (Six Sigma 2017). A defect in Six Sigma is known as anything external to the specifications of the customers. An opportunity in Six Sigma can, therefore, be defined as the total number of chances for the process to have a defect. The sigma of the process can be calculated through the Six Sigma calculator.

The fundamental goal of the methodology of Six Sigma is to implement a strategy that is based on measurement hence improving the process and reduces the variation through the application of improvement projects associated with Six Sigma. This can be accomplished through the two main sub- methodologies of Six Sigma. These are the DMADV and DMAIC processes. The Six Sigma DMAIC process is a system used to improve the existing processes that were below the specified threshold. It is, therefore, used for companies that need an improvement that is incremental.

On the other hand, the Six Sigma DMADV process is an improvement on the system used to make new products and process at the quality level of Six Sigma. It can be employed even when the process needs more than incremental process. Both Six Sigma DMAIC and DMADV processes are conducted through the use of Six Sigma Black Belts and Six Sigma Green Belts. The Six Sigma Master Black Belts is used to oversee the processes. The Black Belts help the companies save significantly through improving efficiency and effectiveness.

According to Six Sigma (2017), the Black Belts help companies to save approximately $230,000 for each of the projects it engages in. It also ensures the affectivity of the company thus ensuring that it completes up to six projects per annum. In the United States, the average salary of a Black Belt is about $80,000. Integrating it into the production process, therefore, has a significant return on investment. One of the companies that have benefited due to Six Sigma is the General Electric Company.

The company estimates the benefits linked to Six Sigma to be worth $ 10 billion during its initial five years after implementation (Six Sigma 2017). General Electric Limited started integrating Six Sigma in 1995 upon realising that Allied Signal and Motorola had blazed the trail of Six Sigma. After the success, several of the companies in the globe have grown to learn the benefits linked to Six Sigma. CHAPTER 2: LITERATURE REVIEW 2.1 Review Approach The review of the literature was based on rigour, soundness, and relevance of both the quantitative and qualitative research material.

In explanation, the literature review was divided into two main sections: Nature and views of the literature review. 2.1.1 Nature of the Literature Review The study entailed a critical evaluation of published literature.