Why Six Sigma Is Not Working
And How to Change It: A Pragmatic Guide for Asset-Intensive Industries
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Six Sigma works exactly as advertised on the factory floor it was built for. This book is about everywhere else.
A Master Black Belt sat through his own certification and heard himself ask the instructor one question: would this make my job easier? The answer was no. What followed was a career spent watching the same statistical toolkit handed to fleets of assets too small, too different, and too expensive to fail for control charts and confidence intervals to mean anything.
Built on a real, named turnaround at a De Beers diamond mine, where FMEA, criticality ranking, and daily walkabouts took the preventive-to-reactive maintenance ratio from 1.1 to 1.6 without a single control chart, this book reforges DMAIC around the asset in front of you instead of the population Six Sigma was built to describe. It is not an argument to throw out the credential. It is the discipline of checking whether the tool fits before the mandate gets written.
Inside:
Chapter 1 — The Factory Floor
Chapter 2 — Sequencing, Not Statistics
Chapter 3 — The Promotion and the Question
Chapter 4 — The Room That Smiled
Chapter 5 — Numbers From Nowhere
Chapter 6 — The Curve Repeats
Chapter 7 — The Room vs. The Floor
Chapter 8 — Koingnaas
Chapter 9 — DMAIC, Reforged
Chapter 10 — It Traveled Without Him
Chapter 11 — How to Change It
Chapter 12 — The Number That Outlives the Project
Chapter 13 — How Far It Travels
Chapter 14 — The Five Questions
Chapter 15 — The Answer Was No
Appendix — The Field Toolkit
Includes The Field Toolkit: three ready-to-use worksheets for ranking criticality, scoring project fit, and checking a project's savings against the asset's own remaining life.
For maintenance managers, reliability engineers, and plant engineers in mining, oil and gas, utilities, and heavy manufacturing.
Details
- Publication Date
- Sep 13, 2026
- Language
- English
- ISBN
- 9781291529524
- Category
- Engineering
- Copyright
- All Rights Reserved - Standard Copyright License
- Contributors
- By (author): Johan Nortje
Specifications
- Pages
- 43
- Binding Type
- Paperback Perfect Bound
- Interior Color
- Black & White
- Dimensions
- US Trade (6 x 9 in / 152 x 229 mm)