Six Sigma Methods & Processes for Manufacturers


Eliminate defects, improve throughput, and reduce costs by applying the principles of Six Sigma. Six Sigma aims to improve quality by finding defects, determining their cause, and improving processes to increase the repeatability and accuracy of process results

Six Sigma is a disciplined, data-driven approach and methodology for eliminating defects (driving toward six standard deviations between the mean and the nearest specification limit) in any process – from manufacturing to transactional and from product to service.

It can improve performance in almost any business, whether the deliverables are products or services. To acheive Six Sigma, a process must not produce more than 3.4 defects per million opportunities. The Six Sigma Define – Measure – Analyze – Improve – Control (DMAIC) process is an improvement system or existing processes falling below specification and looking for incremental improvement.

Originally developed for the assembly line, this methodology has spread throughout the corporate world. Hundreds of consultants offer training, but none can match our experience with small-to-medium-scale manufacturing. Six Sigma Consulting has evolved in a wide variety of settings, and distilled a real-world set of best practices that match the conditions that Pennsylvania manufacturers face every day.

The Catalyst Connection Difference

Our approach introduces best practices, including statistical methods; follows a well-defined sequence of steps; and aims at financial targets such as cost reduction or increased profit. We show leaders how to identify and remove the causes of defects through clearly defined projects, and to follow up with a dedication to continuous improvement.

Six Sigma Tools for Success

The Six Sigma DMAIC Model – Define, Measure, Analyze, Improve, and Control

  • Define:Define the problem and scope a project, how to build a business case to quantify the financial impact of the project to the business, and building a project team.
  • Measure: Identify potential causes to the problem, validate your measurement system with measurement system analysis, and baseline your current process and its capability.
  • Analyze: Determine the correct sample size, data distributions, and a multitude of data analysis tools.
    Improve: Integrate Lean tools with the Six Sigma Consulting.
    Control: Strategies to sustain process improvements. These strategies range from human behavior and resistance to change to the more analytical strategies of statistical process control charts and control plans.

Contact Us

For more information on Six Sigma, contact Eric MacDonald, Managing Director of Continuous Improvement, at 412.918.4210 or