Projects are the Key to Success with Six Sigma

By Kevin Grayson

Six Sigma continues to be a prevalent methodology among many businesses today. As organizations look to become more competitive and increase customer satisfaction, many like the data-driven approach of Six Sigma that seeks to maximize and optimize processes to meet these needs. The stories of Six Sigma generating increased profits and enhanced customer results are numerous.

There are many aspects of Six Sigma that have made it such a favorable approach, but perhaps none is as important as its emphasis on completing projects. These projects start as part of the Six Sigma training process and continue through completion. The projects follow a structured DMAIC approach (see graphic). This allows organizations to review and track projects that may have very different objectives in a very similar manner. The projects also have many beneficial aspects for the company, its customers and the training participants.

For the company, the business can begin to see a very rapid return on investment. Training dollars and deployment efforts can have a clear financial justification. One company we worked with justified the whole first year’s deployment effort – which included numerous training classes -- on just a few projects. Six Sigma projects can also be used to accomplish larger business strategic goals. This allows them to have not only localized, micro-effects but also an influence on larger macro-goals too.

Customers see benefits with a new level of customer service. Whether wait times are reduced, lead times are reduced, or new quality levels are provided, customers see an impact with almost all Six Sigma projects. These often lead to many of the “soft” benefits of projects, like greater repeat business, less price erosion and greater market share.

For the training participants, the projects serve a key component of the training process. Tools and methodology learned in class can be applied on a ‘real-time,’ real-world basis. This ‘apply-your-new-skill-now’ approach both facilitates and accelerates the learning process. Class reviews of the projects, with both participant and instructor feedback, generate questions and suggestions that both strengthen the project as well as the person being trained. Participants learn not only from their project, but also from other projects presented as well. Typically a single project will use just a few tools and methods learned in class, but in the whole class, participants see many tools and approaches used – often in widely different areas.

At NC State, the instructor team will go to the organization’s site as a way to put a final stamp of approval on the project. This on-site project review completes the certification process. This is my favorite part of my job -- to see the tools and methods we have taught in class used in a way that is beneficial to all stakeholders and generate a sense of pride and accomplishment with those who have just started the process a few months earlier.

To maximize your Six Sigma deployment, always include project completion and certification as part of your training process – for both Green Belts and Black Belts.