From GP Deltapoint: Total Six Sigma Implementation and Culture Change

Mike Bresko, Managing Director; and John McNeil, Principal Consultant

Total Six Sigma™ is a GP Deltapoint's holistic system that provides a pathway to operational excellence. It integrates the methodologies of Lean, Six Sigma, and Total Productive Maintenance (TPM) and builds a management system that drives quantum leap improvement and assures effective daily management up and down an organization. This system improves customer satisfaction, streamlines workflow, reduces process variability, and engages people at all levels of the organization.

GP Deltapoint recommends initiating Total Six Sigma implementations with a Model Line or Area. The Model Line allows concentrates projects in one product line or operational area. This approach educates internal consultants (black belts) as they learn by doing; and achieves substantial improvement in cost, quality, and lead-time for the selected value stream.

We use a four-phase approach to implement Total Six Sigma. The first phase - Organize - accomplishes the tasks needed to begin the Model Value Stream Transformation Project. These tasks include engaging leadership, selecting champions and internal consultants, assessing opportunities, and planning the detailed transformation project. The second phase - Stabilize - uses various methodologies to reduce defects and stabilize processes. The third phase - Synchronize - establishes continuous flow and refines process improvements. The fourth phase - Optimize - occurs after the initial Model Value Stream Project. This phase applies more sophisticated analytical techniques, integrates the supply chain, and aligns support systems such as human resources.

As with any large-scale change initiative, organizational and cultural issues play a large part in Total Six Sigma success. Here are ways to avoid pitfalls

• Balance customer needs and cost reduction. Using the methods of Total Six Sigma only to cut costs will not reap the most powerful benefits.
• Build a system for running your business that integrates Lean, Six Sigma, TPM Quantum Leap Improvement and Daily Management. These are powerful allies that together create a more robust and sustainable results.
• Keep a keen eye on what is possible in your organization: challenge people, expect high performance, and set stretch goals. But remember to watch the stress meter.
• Copying the best practices of other companies will not yield results as good as studying other best practices and applying them wisely to your situation.
• A leadership team that is willing to drive decision making down to the lowest effective level, coupled with effective team leadership is the most important predictor of Total Six Sigma success.
• Remember that commitment takes time and everyone's engagement is critical.

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