Six Sigma Theory of Constraints
Six Sigma is a quality program that focuses on near perfection in processes (99.996 out of 100) and the elimination of defects in a process. The Theory of Constraints (TOC) is a methodology used to properly manage the undesirable symptoms in a system through determining what should change, the goals of the change and how to create the change to manage the symptoms. The TOC works to improve the running and functioning of an organization, while Six Sigma is primarily used to perfect the specific processes within the organization.
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History
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Six Sigma as a quality program was created by Bill Smith, an engineer at Motorola, in 1986. He began using product failures as data for understanding how to incrementally improve processes to meet and exceed customer expectations. The TOC was created by Eliyahu Goldratt, a physicist turned business management expert. In his book, "The Goal," published in 1984, Dr. Goldratt explains how to manage an organization around the inevitable constraints that exist.
Knowledge Levels
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The implementation of Six Sigma requires specialized knowledge at varying levels: Yellow Belt, Green Belt, Black Belt and Master Black Belt. The Yellow Belt is a champion or sponsor of a Six Sigma project and removes obstacles to implementation of the Six Sigma project. The Green Belt is responsible for using the Six Sigma methodology and tools in his daily work. The Six Sigma Black Belt is an expert in the use of Six Sigma analysis tools. The Master Black Belt will actually lead a Six Sigma project. The TOC does not contain the same formalized levels of knowledge as Six Sigma; however, training is available.
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Tools
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The Theory of Constraints (TOC) consist of problem-solving and decision-making tools called the Thinking Processes. The Thinking Processes tools assist in identifying assumptions, resolving conflicts and modeling "what-if" analysis. Six Sigma tools use statistics to identify, measure and analyze defects in a process. It is not necessary to be an expert in statistics to use the Six Sigma tools.
Product and Process Design
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Six Sigma has a component entitled Design for Six Sigma (DFSS). The DFSS concept allows for new products and processes to be created using the Six Sigma methodology. The Six Sigma concept is built into the new product offerings. The TOC does not have a component that allows for new products and services. It seeks to work within existing systems and processes. This is a disadvantage of using the TOC.
Tips
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When implementing the TOC or Six Sigma, do not rush the process. Take the time to educate the key stakeholders on each program. Work to obtain "buy-in" from those whose departments are affected by the implementation of the quality programs. Prepare to address the the benefits and disadvantages of each.
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