Six Sigma Training: FAQs and Misconceptions
“The Six Sigmas themselves. Each of them embodies a pillar of the Six Sigma philosophy. Teamwork, insight, brutality, male enhancement, handshakefulness and playhard.” – Jack Donaghy
Six Sigma, probably due to the cryptic choice of name, has generated an aura of mystery, confusion and controversy, perfectly encapsulated in the above quote from US Sitcom 30 Rock. Fortunately (depending on your point of view) the reality of Six Sigma is reassuringly mundane. If you’ve heard of Six Sigma, think it might be relevant to you and want to investigate the option of doing some training, you’ll need to cut through the mumbo jumbo and establish some solid facts.
Luckily we’ve compiled a jargon busting run down of FAQs and common misconceptions on the subject of Six Sigma training.
So who are these Six Sigmas, and what can they teach me?
Let’s begin at the beginning. In the USA in the 1980s Motorola, an electronics manufacturer, developed a business management strategy that set as its goal the standardisation of the manufacturing process and the elimination of defects. A ‘Six Sigma process’ is one that produces 99.99966% of its products defect-free. The term Six Sigma comes from the branch of statistics used to measure manufacturing output (standard deviation from the mean in statistics is usually denoted by the Greek letter sigma, σ). The philosophy behind the strategy came from the realisation that, contrary to expectations, improving the quality of business processes actually leads to the lowering of costs. When combined with previous work on quality improvement, the Six Sigma doctrine emerged as a transferrable methodology for reducing costs through process improvement which is implemented by strong leadership who make decisions based on verifiable data.
Okay. So what’s the ‘Black Belt’ thing about?
A key aspect of the Six Sigma methodology is the emphasis on strong leadership. Top level management in a Six Sigma organisation will be Six Sigma Champions. Below these are Master Black Belts, Black Belts and Green Belts, in order of the level of mastery over Six Sigma concepts and techniques (the names are based on martial arts systems of grading). These individuals are responsible for identifying areas that would benefit from Six Sigma projects then designing and implementing such projects.
That’s all about manufacturing. What relevancy can Six Sigma possibly have for my business?
Six Sigma turns the concept of defect minimisation on its head and looks at it instead as a method of value maximisation. Quality from a product or service is defined as anything that a customer will pay for. Any product or outcome that fails to meet customer expectation is a defect. By reducing the gap between the potential quality generated by any business process and the actual quality that process creates (in other words, by reducing defects) you eliminate waste, cut costs and increase profit. Rather than just cutting costs willy-nilly, Six Sigma teaches you how to use data to identify ways to cut costs while simultaneously improving quality. This can be applied to any business which provides a product or service to a customer through methods which can be analysed and improved. Consultants and free-lancers who want to be able to work with companies who use Six Sigma will also benefit from a deeper understanding of the methods.
How do I get trained in Six Sigma?
There are many companies and independent consultants that offer training in Six Sigma to organisations and individuals. Distance learning options are available but certification, usually accredited by the British Quality Foundation (BQF), requires sitting an exam. Due to the nature of the courses, which teach in depth statistical analysis, a classroom based course gives a much better chance of success.
Where do I start?
If you’re completely new to Six Sigma you’ll probably want to start with an introductory course, unofficially known as the ‘Yellow Belt’, or ‘Green Belt Foundation’. This usually lasts for 4 days and will give you a comprehensive introduction to the core concepts and methodology without going into advanced statistical methods. The next stage is the Advanced Green Belt which teaches the use of statistical analysis tools and associated computer programmes (like Minitab), runs through simulations and case studies on the implementation of Six Sigma methods and leads to certification via a two-hour open book exam.
What if I want to go further?
Black Belt courses and certification will take you to the stage where you can lead the design and implementation of Six Sigma projects within an organisation at a high level. The courses cover advanced tools and feature practical exercises, scenarios and work-based projects. Black Belt courses last for 16 to 20 days and end with a four hour open book examination. Master Black Belt is the next level up and delves further into the whys and wherefores of Six Sigma implementation – the theory underlying the techniques – which will allow you to transfer the methods correctly to new scenarios and manage Black Belts and Green Belts working under you effectively. To upgrade from Black Belt to Master Black Belt you’ll need undertake a further course of 5 to 10 days. If you’re confident with statistical methods and concepts as applied to business, you may wish to enrol on a Black Belt or Master Black Belt straight away – you don’t have to have Green Belt certification in order to go for the Black Belt.
What’s Lean Six Sigma?
Lean manufacturing processes aim to eliminate any expenditure of time and resources that doesn’t provide value for the end customer. Lean Six Sigma is the combination of Lean Manufacturing with Six Sigma methodology which refocuses the decision making of the ‘Lean’ philosophy on statistically sound methods. Lean Six Sigma follows the same course structure as outlined above but is focused on industrial applications.
How much does Six Sigma training cost?
For an individual, Foundation Green Belt courses start from around £1,500 but Advanced Green Belt courses including certification will cost more. A Black Belt course costs at least £3,000 but will probably set you back around £5,000 with another £1,000 to upgrade to Master Black Belt. Minitab software is often not included in the price of courses and will set you back around £1,000 for a single user. You’ll also need to have a laptop you can take with you. In-house training is available for companies who wish to train several staff at the same time. Prices for this will vary between providers so it’s a good idea to get several quotes.
Common Misconceptions about Six Sigma Training
- I’ll do an online course – it’ll be cheaper.
Online Six Sigma training does exist but certification obtained in this way almost certainly won’t be accredited by the BQF or European Organisation for Quality. For that you’ll have to sit an exam and be certified by an accredited body. Also, online courses won’t provide the in-depth practical know how you’ll get from a classroom based course. You could, however, choose to self-study and then take the exam with an accredited practitioner.
- I can only do a course at weekends/evenings.
As far as we know, there are only full-time courses available at present. There are courses starting all the time but they do require a block of at least a few days to complete and take place at training centres in only a handful of UK locations. Bespoke training is available but be prepared to pay a hefty premium. See the previous point about self-study courses.
- You don’t need any prior qualifications.
As we’ve mentioned, Six Sigma courses at advanced Green Belt and higher levels involve in-depth statistical analysis. You’ll need to be comfortable with mathematics of at least A-level standard to get the most out of these courses.
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