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Six Sigma Process Benchmarking and Powerful Tools

By: Jacquelyn Donner

One of the most important tools for achieving Six Sigma process capability is Process Benchmarking. This powerful tool is used to compare processes or products within the industry, between industries, or even between geographical areas or countries. A tool called Benchmarking Chart is a powerful way to "baseline" various processes or products so they may be meaningfully compared.

Companies embarking on the road to Six Sigma adopt a Roadmap which is a four-step process to characterize and optimize their processes to render them virtually impervious to variation. The term Roadmap refers to the need to "breakthrough" the so-called "Five Sigma Wall". It has been shown that progression from 3 to 4 to 5 to Six Sigma capability is exponential, and the jump from 5 to Six Sigma is extremely difficult. Making the first few Sigma gains can be achieved by continuous improvement tools, but "breaking through" the wall requires the implementation of the Roadmap. The Roadmap is divided into four phases. The first phase is Process Measurement, where a "snapshot" is taken of the process to determine the current state of capability. The next phase is Process Analysis, where the data collected in the Measurement phase is analyzed to determine the relationships between the process variables, and determine the direction the process improvement is to take. The third stage is Process Improvement, where certain process input variables, determi-ned in the Analysis phase to be critical to optimum process performance, are subjected to an extremely powerful statistical tool called Design of Experiments. DOE is used to study, in a rigorous manner, the performance of the process at a variety of different input settings. The result is a process which has been optimized to run at peak efficiency, on target, with a minimum of variation.

The final stage of the Roadmap is Process Control, where the tools of Statistical Process Control are brought to bear on the optimized process. The process is monitored on an on-going basis to ensure the process itself does not begin to vary from the optimized state achieved during Phase Three, Improvement. Six Sigma is a process reengineering methodology which has been embraced by Bombardier and will be implemented throughout the organization in the coming years. It will result in major shifts in our ways of thinking and our ways of doing business, and will ultimately lead to quantum leaps in process and product quality. Producing superior products, delivered in a timely manner and at the best possible price will translate into highly satisfied customers and marketplace domination.

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Jacquelyn Donner, Master Six Sigma Black Belt

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