Efficiency & Motivation

How to use Six Sigma to improve processes and reduce errors in your projects?

Want to achieve near-perfect quality in your projects and processes? Six Sigma is a data-driven method that enables companies like Motorola and General Electric to significantly reduce errors and achieve substantial savings. Find out what it’s all about.

In this article, you will learn: What Six Sigma is When to use it How DMAIC and DMADV differ How it boosts project efficiency What tools support data analysis How software helps with implementation

What is Six Sigma and how does it work?

In our project glossary, Six Sigma is a management strategy that strives for near-perfect quality by reducing errors in processes. Its name refers to a very high level where only 3.4 defects per million opportunities occur, indicating process stability. The method originated at Motorola in the 1980s. The company, to address quality issues and competition, implemented a program to enhance product and process quality.

When is worth implementing Six Sigma? Industries where continuous improvement is a must

The method works best in processes with high variability and high error costs, as well as in environments that require continuous improvement. Six Sigma implementation helps identify causes of variability and implement corrective actions, stabilizing the process and reducing defects. It promotes a data-driven culture, fostering continuous optimization. 

• In manufacturing, the application of Six Sigma translates into effective defect reduction, optimizing production lines, minimizing material losses and reducing cycle times. 
• In logistics, Six Sigma supports the optimization of supply chains, effectively reducing errors in order picking and shortening delivery times. The method improves inventory accuracy.
• In banking, it helps reduce transaction errors and improve customer service. In healthcare, it supports reducing medical errors and optimizing patient admission processes.

The core of Lean Six Sigma: DMAIC vs DMADV

In the Lean Six Sigma methodology, there are two main approaches to projects: DMAIC and DMADV. Both are used for process improvement and their choice depends on the strategic project goals.

	DMAIC (Define, Measure, Analyze, Improve, Control)	DMADV (Define, Measure, Analyze, Design, Verify)
Main goal	Improving existing processes	Designing new processes/products/services
When to use this method?	When a process is faulty, it needs to be optimized	When a process/product doesn’t exist or needs a major redesign
Stages	Define, Measure, Analyze, Improve, Contro	Define, Measure, Analyze, Design, Verify
What is the focus?	Reducing variation and defects in an existing process	Creating a stable, high-quality process from scratch
Main question	How can we improve what we already have?	How can we design something that will work perfectly?
Expected result	An optimized, more efficient process	New, high-quality process/product/service

 

How Six Sigma improves project performance?

Lean Six Sigma improves processes and quality by removing errors and waste. It’s an analytical approach to continuous improvement that increases efficiency and customer satisfaction. PRINCE2, on the other hand, is a project management method focused on project structure, organization and control, defining roles and milestones. In summary: Lean Six Sigma improves operations, while PRINCE2 manages a project to achieve its goals. The two methods can work together, such as Six Sigma optimizes processes in a PRINCE2 project.

Six Sigma supports Kanban management because both methods seek to streamline work and eliminate waste. Six Sigma analyzes problems evident in Kanban (e.g., using Pareto diagrams) to get to the root of the problem. By reducing variability, it ensures a smooth workflow and better predictability of delivery. Six Sigma’s DMAIC phases are a perfect fit for continuous improvement in Kanban, streamlining the various steps. Six Sigma provides tools to collect and analyze data to help make better decisions in Kanban. By combining Kanban’s visual control with Six Sigma’s analytical approach, companies gain greater efficiency and fewer errors in projects.

The role of data and statistical tools in Six Sigma

The method is based on facts, not assumptions. With quantitative analysis, processes are better understood, controlled and improved. Without collecting and interpreting data, it is impossible to find the causes of problems, measure progress or check the effectiveness of solutions. The table below shows 7 classic quality management tools that support these activities

Tool	Applications	Functions
Process map	Visualize a sequence of tasks in the process	Shows structure and relationships, helps find weaknesses
Ishikawa (“fishbone”) diagram	Identify and solve problems by looking for root causes	Illustrates the complexity of the situation and the connections between factors, helps analyze causes
Pareto diagram	Identification and classification of problems; separates important causes from trivial ones	Helps focus on key issues (80/20 rule), monitors results and effectiveness of activities
Histogram	Graphical representation of the distribution of a trait variable in a population	Visualizes the variability of process results, indicates areas for improvement, shows process information
Correlation (scatter) diagram	Detection of cause-and-effect relationships between variables	Visually shows the strength of correlations, allows you to observe relationships between parameters
Control sheet	Compilation of collected data to detect dominant trends	Quantitative evaluation of the course of the process, comparison of historical / current data, short preparation time, low cost, high efficiency
Control card	Continuous control of the process and monitoring of its variability	Finds deviations affecting quality, distinguishes special causes from random causes, helps predict changes and take corrective action

Implementing Six Sigma with digital tools

Six Sigma implementation is much more efficient with project management tools. With FlexiProject, implementing this method becomes simpler because all the necessary functions are available in your project management system. The tool offers:

• Precise task planning and Gantt chart monitoring.
• Workflow automation, allowing you to assign tasks and track their completion, increasing efficiency.
• Central storage of all project documents and data, making them easy to access.
• Visualize key performance indicators (KPIs) and defect reduction progress with dashboards and reports.
• Support in effective resource management and cost control.
• Facilitated communication and team collaboration.