Manage application of six sigma for process control and improvement

This unit of competency covers the skills and knowledge required to manage six sigma in the workplace for the purposes of process control and process improvement.


This unit covers the skills and knowledge needed by a technical expert in managing the application of six sigma in an organisation in order to minimise defects and make improvements to processes and/or products. Depending on the need the expert will apply six sigma processes themselves or work with, and advise, other employees in applying six sigma processes.

This unit requires the application of skills associated with problem solving, initiative, enterprise, planning and organising in order to apply six sigma in the workplace. This unit requires skill in gathering, analysing and applying information and data.

Depending on the situation of the enterprise and the complexity of their operations process the following units may also be required in implementing six sigma at an enterprise:

MSS403010A Facilitate change in an organisation implementing competitive systems and practices

MSS403051A Mistake proof a production process

MSS404081A Undertake proactive maintenance analyses

MSS405002A Analyse and map a value stream

MSS405011A Manage people relationships

MSS405050A Determine and improve process capability

MSS405052A Design an experiment

MSAPMSUP390A Use structured problem solving tools.


MSS403052A Apply statistics to operational processes

Elements and Performance Criteria


Review process data


Confirm area of responsibility/study with executive leaders and other stakeholders


Review statistical process control (SPC), process capability and other relevant data for area of responsibility/study


Identify shifts in process performance and processes requiring improvement


Quantify the shifts in performance which have occurred or which are desired


Determine cost of shift in performance and cost of intervention


Identify improvement priorities and degree of intervention


Apply define, measure, analyse, improve, and control and standardise (DMAIC) process to priority areas


Define improvement project


Determine if a six sigma project team is to be established or project undertaken individually


Determine metrics and acquire initial data


Analyse data and determine possible causes of performance shifts/process improvements


Develop and trial improvement solutions


Control and standardise the improvement


Establish/review control strategies


Determine sampling schedule


Analyse data to determine process capability


Develop process control strategy


Confirm strategy with all stakeholders


Identify skills required to implement and monitor process control strategy


Arrange training, where required, for employees in skills and techniques needed for process control strategy


Review and confirm improvement


Calculate and document benefits


Ensure procedures and other relevant documentation is updated for improved procedure


Review process data after an appropriate period and confirm the improvement

Required Skills

Required skills

Required skills include:

identifying and defining six sigma projects

developing procedures for collection and analysis of data

reporting and presenting data and quantitative information

analysing priorities and improvement projects and determining where individual or team effort is required

determining and completing appropriate charts for a project

communicating and explaining DMAIC methods to others

leading a six sigma project team

documenting and reporting six sigma project benefits in both statistical (defect reduction) and benefit/cost terms

Required knowledge

Required knowledge includes:

charting, including:

Pareto charts

fishbone diagrams

PICK charts

run charts

scatter diagrams

statistical principles and analysis, including:

confidence limits

analysis of variance

presentation data:

frequency distribution tables


measures of central tendency:

arithmetic mean



measures of dispersion:

standard deviation


interquartile range

correlation and dependence

acceptance criteria/confidence levels

DMAIC methods

failure mode and effects analysis (FMEA)

process mapping

suppliers, inputs, process, outputs, customers (SIPOC) mapping

types of data (e.g. discrete/continuous/attributes) and their use in six sigma

Evidence Required

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

A person who demonstrates competency in this unit must be able to provide evidence of the ability to:

analyse statistical data and identify significant variations and other indicators for potential six sigma projects

apply DMAIC process individually

lead others in DMAIC process

review control strategies

confirm improvements.

Context of and specific resources for assessment

Assessment of performance must be undertaken in a workplace using or implementing one or more competitive systems and practices.

Access may be required to:

workplace procedures and plans relevant to work area

specifications and documentation relating to planned, currently being implemented, or implemented changes to work processes and procedures relevant to the assessee

documentation and information in relation to production, waste, overheads and hazard control/management

reports from supervisors/managers

case studies and scenarios to assess responses to contingencies.

Method of assessment

A holistic approach should be taken to the assessment.

Competence in this unit may be assessed by using a combination of the following to generate evidence:

demonstration in the workplace

workplace projects

suitable simulation

case studies/scenarios (particularly for assessment of contingencies, improvement scenarios, and so on)

targeted questioning

reports from supervisors, peers and colleagues (third-party reports)

portfolio of evidence.

In all cases it is expected that practical assessment will be combined with targeted questioning to assess underpinning knowledge.

Where applicable, reasonable adjustment must be made to work environments and training situations to accommodate ethnicity, age, gender, demographics and disability.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the oracy, language and literacy capacity of the candidate and the work being performed.

Range Statement

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Competitive systems and practices

Competitive systems and practices may include, but are not limited to:

lean operations

agile operations

preventative and predictive maintenance approaches

monitoring and data gathering systems, such as Systems Control and Data Acquisition (SCADA) software, Enterprise Resource Planning (ERP) systems, Materials Resource Planning (MRP) and proprietary systems

statistical process control systems, including six sigma and three sigma

Just in Time (JIT), kanban and other pull-related operations control systems

supply, value, and demand chain monitoring and analysis


continuous improvement (kaizen)

breakthrough improvement (kaizen blitz)

cause/effect diagrams

overall equipment effectiveness (OEE)

takt time

process mapping

problem solving

run charts

standard procedures

current reality tree

Competitive systems and practices should be interpreted so as to take into account:

the stage of implementation of competitive systems and practices

the size of the enterprise

the work organisation, culture, regulatory environment and the industry sector


DMAIC is a structured improvement methodology for existing business processes involving the following stages:





control and standardise


Definition of the project to include:

completed, verified and validated as in process map

SIPOC diagram

discrepancies to current 'as is' process map

formation and briefing of project team

defining business case for project

problem statement

goal statement

project scope


Metrics may include:

key measures/attributes

sampling schedule for project

defect rate


Analyse may include:

statistical analysis of data

root cause analysis


use of various other problem solving/analysis tools


Improve may include:

generating and testing of improvements

selecting appropriate improvements

Control and standardise

Control and standardise may include:

documenting outcomes and procedures for standardisation

transferring ownership of improved process

Sampling schedule

Sampling schedule may include:

sampling frequency

type of sample/sample method

sample location/type

type of test/data to be collected

Process control strategy

Process control strategy may include:

degree of intervention/rules for resets

SPC tools to be used


Unit sector

Competitive systems and practices

Employability Skills

This unit contains employability skills.

Licensing Information

Not applicable.