October 2006

"Quality Focus" - monthly Genesis column

Problem Prevention Rather than Repair

Straightforward Six Sigma programs are being replaced by Design for Six Sigma, a more proactive version...

Most of us are familiar to one degree or another with the Six Sigma philosophy, or at least we should be.  If you are involved in any way with the can industry, such knowledge is not a luxury: it is becoming an eventual job requirement. 

However, Six Sigma will one day be a thing (mostly) of the past.  What?  How can that be?  Because it is today’s program that will fade like the rest of them?  No, on the contrary because it is only becoming bigger and better. 

But wait, is that not a contradiction?  How can something be fading away and simultaneously strengthening?  Good question. 

Six Sigma, in its traditional form, takes the tact of Define a problem, Measure it, Analyze the (statistical) data, Improve the situation (or process), and Control it going forward – DMAIC.  Several companies in our industry are using it to gain a competitive advantage, while some are still trying to convince themselves it is the programme du jour.  Keep in mind, though, that Six Sigma DMAIC is in reality a reactive philosophy, in that we address existing problems, in our case mostly within can production.   

We all know that problems surface every day on a line.  We all also know there are many methods utilized to correct our production problems.  However, we unfortunately know the problems will sometimes reappear.  This is where Six Sigma methods come to the forefront to enable the eradication of these issues once and for all. 

However, would it not be nice if a can line could be installed that exhibited no issues?  Okay, perhaps that is a stretch at this point in time, so let us be a little more realistic and ponder whether a single piece of canmaking equipment (or a material, for that matter) could start up trouble-free.  But that is impossible, right? 

Enter the realm of Design for Six Sigma, or DFSS.  This is where the most progressive manufacturing companies are headed – in all industries.  DFSS espouses a proactive philosophy whereas trouble-free performance is built in from the start.  It takes DMAIC “tools” and integrates them into a product development methodology intended to deliver the right product to the customer that both produces a quality product and itself exhibits reasonable longevity and operability.

However, one of the common themes related to me by suppliers in all industries – not just ours – is their inability to “take the time to perform DFSS.”  I am often told they would “rather fix it in the field,” even at greater cost than doing it right the first time, in addition to providing their customers with needless aggravation.  This is a philosophy against which no argument will suffice.  One cannot see the solution without first seeing the problem – someone famous said that, I believe. 

It is DFSS that will (theoretically) one day make Six Sigma DMAIC obsolete.  After all, if you are fortunate enough to eventually have all your suppliers performing DFSS, what will your Six Sigma “black belts” do?  Hopefully you will be moving them from your operations to your suppliers’ to ensure that what is supplied to you is indeed capable of Six Sigma performance. 

Given the external competition against cans, our industry must offer exceptional value to its customers.  Many are now doing that via Six Sigma DMAIC.  Some are forging ahead into DFSS to ensure tomorrow’s cans provide another incremental increase in value.  If you are performing DMAIC, keep up the good fight!  DFSS?  You are indeed “cutting-edge.”  Doing nothing?  Well, there’s always luck…