This should be at the rate of one black belt and two green belts for every 140 employees, ideally. Similarly for every 800 employees it is advisable to have a Master Black Belt who would coordinate the whole project and we should be able to nominate a champion to take things forward.
2. Tolerance of variation needs to be established. During the course of the process study one of the important measures that need to be achieved would be to identify to what extent errors during the implementation of the six sigma could be tolerated. Variations could be in multiple areas of operation, in design, by design, customer acceptance, etc.,
3. Slack in the availability of the human resources. It is very difficult to free a person in its entirety for the initiative. We need to look at allocating one day per week of every person. Working out the total time spent in terms FTE (Full-Time Equivalents) would help us in judging whether to have full time change agents in the company and to also decide how many of them we will adopt for this purpose.
4. 4. We need to identify the technical expertise that we will be relying in during the course of the implementation. We will require an expert statistical analyzer who would help us in applying varied statistical principles and help in determining the best possible alternatives during the production process. The principle here is to ensure that the process is as simple as possible. (KISS - Keep It Simple, Stupid) and every one is able to appreciate it. We would also require to master some of the design and would possible involve ourselves in Design Of Experiments, adding valuable data to our repository.
5. Set realistic time lines and realistic targets at every milestone.
3.0 Training the Change Agents
In order to have an effective six sigma implementation, the right kind of people should be nominated to the implementation process. Most often, it is the best people that a company has, who needs to be on it. Identifying the change agents should ideally start from the lower level, the Green Belts. They should be put through the Green Belt training and they should be ranked and the initiation of the implementation process is taken up. Once this is done, the understanding of the technicalities involved is also rated among the green belts and they are further identified for the black belt jobs. Black belts are trained further and rated for one senior person to spear head the entire process by being the Master Black Belt and the Champion for the entire project.
A hierarchical structure aimed at creating a separate six sigma organization is made starting at the ground level with green belts moving up to the black and then the master black belts.
4.0 Execution Methodology