Six Sigma: A Sample of How it Works

I'm trying to briefly show how Six Sigma works. However the actual implementation would not be as simple as it is written here. This is just for an informative purposes only. 

Problem statement:

A global consumer goods company is experiencing a high rate of defects in its manufacturing process, resulting in lost revenue and decreased customer satisfaction. The company decides to implement Six Sigma to improve quality and reduce costs.

DMAIC process:

The company implements the DMAIC process to address the quality issues in its manufacturing process.

1. Define: 
   The team defines the problem, project goals, and customer requirements. They also identify key stakeholders and establish a project charter. For example, the team may define the problem as "high defect rates in our manufacturing process that are causing lost revenue and customer complaints" and establish a goal of reducing defects by 50% within six months.
2. Measure: 
   The team collects and analyzes data on defect rates, customer complaints, and other quality metrics. They use tools like statistical process control charts and Pareto analysis to identify the most common defects and prioritize their efforts. For example, the team may find that the most common defects are related to a specific component in the manufacturing process.
3. Analyze: 
   The team conducts a root cause analysis using tools like fishbone diagrams and statistical analysis to identify the underlying causes of the defects. They discover that the primary causes are variations in the component specifications, lack of operator training, and inadequate quality control measures. For example, the team may find that there are inconsistencies in the specifications for the component that are causing variations in the manufacturing process.
4. Improve: 
   The team develops and implements solutions to address the root causes of the defects. They work to standardize the manufacturing process, provide additional training for operators, and implement more robust quality control measures. For example, the team may work with suppliers to standardize the component specifications, develop a training program for operators, and implement a new quality control system.
5. Control: 
   The team establishes control measures to sustain the improvements and prevent the defects from recurring. They implement ongoing monitoring and measurement systems to ensure that the manufacturing process remains stable and that any issues are quickly identified and addressed. For example, the team may implement a system of regular audits to ensure that the manufacturing process is adhering to the new standards and that operators are properly trained.

Results:

After implementing the Six Sigma project, the company is able to reduce defect rates by 60%, resulting in a significant reduction in customer complaints and an increase in customer satisfaction. The company is also able to reduce manufacturing costs and increase revenue by improving efficiency and reducing waste. For example, the company may save on raw material costs due to the improved manufacturing process. The Six Sigma project leads to increased competitiveness in the market and improved financial performance for the company.