The implementation of a Six Sigma project requires the services of professionals who are well trained in using the various tools and techniques of Six Sigma. Such professionals have to undertake a certification program or training on the various Six Sigma measurement tools and techniques they can bring into practice.
Six Sigma certification is similar to other certification programs, and a certified professional is capable of utilizing their knowledge to the benefit of the organization. There are various levels of certification that can be achieved after the appropriate tests are passed.
These levels are named in the same manner as martial arts grades; Green Belts, the Black Belts and Master Black Belts.
The Green Belt
This is the basic level that is completed when an individual completes two weeks of training and passes the qualifying exam. All the basic essential methodologies are taught in this level, such as DMAIC and its overall usage.
Green Belt training also covers project management, quality management tools and quality control tools. It also trains students on problem solving and data analysis methods.
Green Belts are also trained in implementing deployment plans and ways to sustain the new changes that have been introduced.
The Black Belt
Black Belt certification is given to a technically-oriented professional who completes four weeks, or around 160 hours of training and passes the appropriate test. This curriculum covers Green Belt certification curriculum as well. Black Belts generally have a background in college level mathematics, which is relevant for quantitative analysis in various phases of Six Sigma projects.
They are also proficient in using software tools, spreadsheets, databases, presentation software and so on. They may also be trained in the usage of statistical analysis software and simulation tools. These individuals also undertake project work and usually train other Six Sigma trainees and Green Belts.
Black Belts develop their skills in cross-functional Six Sigma project implementation. They then move on to undertake the role and responsibility of Six Sigma team lead.
The Master Black Belt
This is the highest level of organizational proficiency. Master Black Belts are those individuals who undertake the four weeks training and implement it as program managers. They have all the knowledge and training that Black Belts have - and even more skills to understand the mathematical theory of the various statistical tools in use.
They may also be proficient in project management, imparting training, program organization and so on. They should have the ability to guide the Black Belts in applying the various techniques correctly in critical areas. They should have good communication and training skills, as they are generally responsible for imparting training on the various statistical tools and techniques to the Black Belts and Green Belts.
They should assist others in achieving their certifications, thus reducing the extra cost of training these individuals.
Not all certified professionals have the same levels of competencies for undertaking the implementation of Six Sigma projects. By training for various levels, individuals can develop their competencies and become important participants of the various levels of Six Sigma project implementation.
Six Sigma Training And Certification
One of the root causes of excess and obsolete inventory is the poor and inaccurate forecasting of the required levels. Long lead times and poor quality are high-level causes of such problems.
When lot sizes are large, the lead time also increases; it may also increase if the schedules go off track, there is late delivery and processes are complicated or need a lot of rework. If there is poor demand management (i.e. when the demand and supply do not match due to inaccurate demand data, poor forecasting and unrealistic sales projections), there is excess inventory.
Lean Six Sigma can be used to reduce waste and rework, process workflow to reduce the inventory excesses and obsolete inventory pile-up. It can also be used to improve the quality levels so that the diverse factors causing waste within the workflow can be eliminated.
Using Lean Six Sigma to Tackle Root Causes
Lean Six Sigma teams can make use of the DMAIC methodology to find the root causes of the problem of excess and obsolete inventory. Using some of the excel-based inventory models and other software, they can easily determine the key process input variables of the problem, by following the general Six Sigma root cause philosophy of Y=f (x) to analyze and identify the problem areas.
They can also be used to show sales, marketing, manufacturing and other functions in the supply chain where the functions are responsible for the high lead-time, and consequently improve on demand management practices.
In improvement projects, teams start by analyzing the inventory and defining the project goals. These goals are the guidelines for the team for system operations. Data fields are based on the questions and IT systems are used to design an inventory model to find the root causes of the inventory problem.
In the next Measure phase, a measurement system and data collection plans are made. An on-site physical count of inventory and a management report analysis is also done to determine the accuracy of supply chain metrics such as lead time, lot size, etc. In the Analyze phase, using the inventory models, the key process input variables that have an impact on inventory management are identified.
A simple inventory balance may also be used to calculate service levels, lead time and demand variation. This helps to identify which items and which locations have too much or too little inventory. All this helps determine the root causes of the problem.
In the Improve phase, the measures to overcome such problems are identified and utilized to bring about improvements in the system.
There are other problems that are identified in the analysis and execution of such projects. Lean tools such as 5S can be used in the Control phase to sustain the improvements over a period of time.
Inventory models can also be utilized to reflect the supply chain functions and show the effect of demand management practices on the excess and obsolete inventory. Companies can use Lean Six Sigma to reduce and eliminate waste in inventory and streamline the entire company's operations.
Tony Jacowski has sinced written about articles on various topics from University, Six Sigma and Information Technology. Tony Jacowski is a quality analyst for The MBA Journal. Aveta Solution's Six Sigma Online offers online and certification classes for six sigma pro. Tony Jacowski's top article generates over 90500 views. to your Favourites.
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