PART 6 CONTROLLING554
and statistical quality control. The reason for using quality circles is to push deci-
sion making to an organization level at which recommendations can be made by the
people who do the job and know it better than anyone else.
Benchmarking Introduced by Xerox in 1979, benchmarking is now a major TQM
component. Benchmarking is de ned as “the continuous process of measuring
products, services, and practices against the toughest competitors or those compa-
nies recognized as industry leaders to identify areas for improvement.”
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The key to
successful benchmarking lies in analysis. Starting with its own mission statement,
a company should honestly analyze its current procedures and determine areas for
improvement. As a second step, a company carefully selects competitors worthy of
copying. For example, Xerox studied the order ful llment techniques of L. L. Bean,
the Freeport, Maine, mail-order rm, and learned ways to reduce warehouse costs by
10 percent. Companies can emulate internal processes and procedures of competi-
tors, but must take care to select companies whose methods are compatible. Once a
strong, compatible program is found and analyzed, the benchmarking company can
then devise a strategy for implementing a new program.
Six Sigma Six Sigma quality principles were rst intro-
duced by Motorola in the 1980s and were later popularized
by General Electric, where former CEO Jack Welch praised
Six Sigma for quality and ef ciency gains that saved the
company billions of dollars. Based on the Greek letter sigma,
which statisticians use to measure how far something devi-
ates from perfection, Six Sigma is a highly ambitious qual-
ity standard that speci es a goal of no more than 3.4 defects
per million parts. That essentially means being defect-free
99.9997 percent of the time.
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However, Six Sigma has devi-
ated from its precise de nition to become a generic term for
a quality-control approach that takes nothing for granted
and emphasizes a disciplined and relentless pursuit of
higher quality and lower costs. The discipline is based on
a ve-step methodology referred to as DMAIC (De ne,
Measure, Analyze, Improve, and Control, pronounced “de-
May-ick” for short), which provides a structured way for
organizations to approach and solve problems.
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Effectively implementing Six Sigma requires a major
commitment from top management, because Six Sigma
involves widespread change throughout the organization.
Hundreds of organizations have adopted some form of Six
Sigma program in recent years. Highly committed compa-
nies, including ITT Industries, Motorola, General Electric,
Allied Signal, ABB Ltd., and the DuPont Company, send
managers to weeks of training to become quali ed as Six Sigma “black belts.” These
black belts lead projects aimed at improving targeted areas of the business.
47
Although
originally applied to manufacturing, Six Sigma has evolved to a process used in all
industries and affecting every aspect of company operations, from human resources to
customer service. Textron, whose products include Cessna jets and E-Z-Go golf carts,
has trained nearly 10,000 in-house experts in Six Sigma and uses it in both its manufac-
turing and service sectors. Textron CEO Lewis Campbell offers proof that it’s working.
“Even though Cessna has been producing planes for 89 years and jets since 1972, they
recently reduced by 17 percent the labor hours required to make their single-piston
aircraft. That’s a big number. They’ve taken the inspection time from 10 days to ve.
Textron nancial used to take 320 hours each month collecting interest from customers.
They’ve got that down to 56 hours.”
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Exhibit 18.8 lists some statistics that illustrate
why Six Sigma is important for both manufacturing and service organizations.
The idea for “Unwind” events,
such as this performance of traditional dance in the lobby of
the Westin Kuala Lumpur in Malaysia, came from the staff of
the Westin Chicago River North as a way to improve profi t-
ability and guest service. Unwind events are aimed at business
travelers and designed to encourage guest interaction. Six
Sigma specialists at each unit of Starwood Hotels & Resorts
Worldwide facilitate the development of projects from the ideas
of local staff. After rolling out a prototype, performance met-
rics are used to gauge the success or failure of the new projects.
The Unwind program alone produced 120 new events, one for
each Westin hotel.
COURTESY OF STARWOOD HOTELS & RESORTS WORLD-
WIDE; PHOTO PROVIDED BY BUSINESSWEEK
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