Six Sigma Cultural Change Implementation
Motorola includes three methodologies under the Six Sigma umbrella. Two focus on Quality. They are Design for Manufacturability and Utilizing the Six Steps to Six Sigma. The third, Cross Functional Process Mapping, focuses on Cycle Time Reduction. They are "key initiatives" that are used to drive continuous improvement toward Total Customer Satisfaction.
The Motorola University Consulting and Training Services organization and now MASET have worked with several organizations to help them implement Six Sigma. The assistance contained the same basic elements, although each element was tailored to meet the individual needs of each organization.
REVIEW OF MOTOROLA'S QUALITY JOURNEY
- Attendees would be the Top Management of the organization.
- This three-day session covers the three major methodologies used, allows for discussion and evaluation of their application to the organization, and the establishment of goals for the organization. If applicable, the implementation plan is then developed.
MANAGEMENT TRAINING SESSIONS (CUSTOM DESIGNED)
- Attendees would be both Top Management and Senior Management.
- One day. Management role in the implementation of Six Sigma.
- One day. If not previously done, review of Motorola Quality journey.
- Two days. "Design for Manufacturability" (ENG123 is the Motorola course designator). This course covers the methodology that we use to apply Six Sigma concepts to the design and manufacture of physical products.
- One day. "Utilizing the Six Steps to Six Sigma" (SSG102). This course trains participants in the methodology that Motorola/MASET uses to apply Six Sigma concepts to administrative or transactional work.
- One day. "The Behavioral Aspects of Cultural Change."
- One-half day. "Cross Functional Process Mapping". A review of the methodology used to reduce the cycle time of our major business processes.
- One-half day. A review of how the methodologies would be implemented across the organization's businesses, and how the participants will apply the concepts to their own work.
Because significant cultural change is usually required for successful implementation of Six Sigma, we recommend a phased implementation plan. In Phase I, a small number of formal projects are chosen for implementation. These projects are used to drive the use of all three methodologies in key areas of the organization. Projects should be selected that address customer satisfaction issues, are critical to the success of the business, and are expected to return significant financial benefits. Regular detailed review of Project progress by Top Management is required to ensure that Six Sigma implementation receives the appropriate priority from the whole organization. Once the Phase I Projects are successful, additional projects are selected in phases until the methodologies are internalized by the organization, and their use becomes institutionalized throughout the organization.
We recommend the selection of instructors to support the "Design for Manu-facturing" (DFM) and "Utilizing the Six Steps to Six Sigma" (SSSS) project teams.
The basic requirement for these instructors is to be certified to teach the associated course. The instructor certification process involves the following steps:
- Attend an "Instructor Training" course that develops the skills needed to present information effectively.
- Observe a MASET instructor teach either the DFM or SSSS course.
- Attend a "Train the Trainer" session for either DFM or SSSS.
- Co-teach a DFM or SSSS class with a MASET instructor to demonstrate content knowledge and "teaching" proficiency.
- Provide training in team dynamics and managing projects.
Facilitation skills are also very important; therefore, development of facilitation skills is also a requirement. MASET can also provide help in this area.
The instructors will then assist project teams in the use of the DFM or SSSS methodologies during the life of the projects. As instructors they will be able to help with team dynamics, and the recognition that additional specific training is required to help teams move beyond any barriers they encounter.
As additional projects are selected and further DFM or SSSS training is required, the instructors will be able to deliver that training.
PROJECT TEAM TRAINING
Members of project teams that will use the DFM or SSSS methodologies receive training in those methodologies before their projects start. As projects progress, additional training might be required in Problem Solving Techniques, Statistical Methods, etc.
During Phase I Applications Assistance would be provided by MASET Consultants at regular reviews of the projects. This ensures that the teams use the methodologies effectively and that the organization gains the maximum benefit from each project. As the instructors become experienced in either the DFM or SSSS methodologies and assisting teams with projects, they will be able to provide ongoing applications assistance in later phases.
As the organization's Quality Performance improves beyond 5 Sigma and approaches 6 Sigma, the use of more advanced statistical tools will be necessary to continue the improvement. This is when the organization will need individuals with broad knowledge of advanced statistics, application experience, and the ability to mentor. These "Blackbelts" must be available to provide assistance to teams when required, for however long that assistance is required, although they do not necessarily have to be assigned to the Blackbelt role full time.
MASET trains its Blackbelts using a "sandwich" type course. The trainee learns a particular statistical "tool", uses that "tool" in a project environment, and then reports on the results, before advancing to learn the next "tool". This extends the training over a 42-month period.
Successful implementation of Six Sigma usually requires that an organization make significant changes in the way it operates. We believe that the cultural change required mandates that Change Management is an essential element in the plans for implementation. MASET has specialists in Organization Development who can assist in planning the Change Management strategy.
Six Sigma is a service mark of Motorola Inc.
MASET, LLC P. O. Box 11663 Chandler, AZ 85248
Phone: 602-721-3680 Fax 480-802-4710