Six Sigma: When Sometimes Things Go Wrong, and Six Sigma Results in Failure

If you wonder what is a sample situation of a failed Six Sigma implementation, I have it here. Although this is a proven to be a successful method, but it need to be implemented properly by a team of qualified personnels. Let's see how easily things go to a wrong direction.

Problem statement:

A manufacturing company is experiencing a high rate of defective products, resulting in increased costs and decreased customer satisfaction. The company decides to implement Six Sigma to improve product quality and reduce defects.

DMAIC process:

The company implements the DMAIC process to address the issue of defective products.

1. Define: 
   The team defines the problem, project goals, and customer requirements. They identify key stakeholders and establish a project charter. For example, the team may define the problem as "a high rate of defective products that is resulting in increased costs and decreased customer satisfaction" and establish a goal of reducing defects by 50% within six months.
2. Measure: 
   The team collects and analyzes data on defective products, including the type of defect, location, and production line. They also conduct a survey of customers to gather information on their satisfaction with the company's products. For example, the team may find that the majority of defects occur on a particular production line and that customers are dissatisfied with the company's response to quality issues.
3. Analyze: 
   The team conducts a root cause analysis using a fishbone diagram to identify the underlying causes of defects. They discover that the primary causes are related to equipment failures, operator errors, and supply chain issues. For example, the team may find that outdated equipment on the production line is contributing to defects, operators are not properly trained on quality control measures, and suppliers are providing subpar materials.
4. Improve: 
   The team develops and implements solutions to address the root causes of defects. They invest in new equipment, provide additional training for operators, and work to improve supplier relationships. For example, the team may purchase new machinery for the production line, provide training for operators on quality control measures, and establish more stringent supplier quality control measures.
5. Control: 
   The team establishes control measures to sustain the improvements and prevent defects from recurring. They implement ongoing monitoring and measurement systems to ensure that product quality remains high and that any issues are quickly identified and addressed. For example, the team may implement regular quality audits and conduct surveys of customers to monitor their satisfaction with the company's products.

Results:

Despite the team's efforts, the Six Sigma project does not lead to a significant reduction in defects or an improvement in customer satisfaction. The company's costs actually increase as a result of the new equipment purchases and additional training expenses. The root cause analysis may have been incomplete, and the team may not have fully understood the causes of the defects. The improvements made may not have been well-suited to the specific issues faced by the company, or the control measures may not have been effective in sustaining the improvements. Ultimately, the Six Sigma project is considered a failure, and the company may need to consider alternative quality improvement strategies.