Six-Sigma is a standard way to score how consistent a
process — or in this case, a worker — is. Higher σ levels
mean more predictable, safer, more productive work.
How we apply it here
On a shop floor the most useful "process" to measure is the
worker themselves: are their delivery cycles repeatable, do
they stay clear of the machining zone without PPE, and do
they keep to a safe walking pace? Each worker gets a score
on three components, then we average them.
- Cycle consistency — variance of transit time
between pickup and dropoff across the worker's deliveries.
Low variance = high σ. A worker with zero deliveries
scores 0 here, not a neutral middle — non-production is a
real signal, not a free pass.
- PPE compliance — fraction of the worker's frames
that were outside the machine zone. Because neither worker
in this scene is wearing PPE, the rule simplifies to "any
time spent in the machine zone is a violation."
- Speed compliance — fraction of frames at or below
a normal walking pace (~1.5 m/s p95). Sprinting or chasing
equipment counts against the score.
The three components are averaged and scaled to a 0–6σ range.
The same number is shown on each worker card and aggregated
into the workforce σ at the top.
The benchmarks
- ~5σ and up — benchmark performer. Consistent
cycle times, no PPE violations, no overspeed events.
- ~4σ — workforce-typical. Some variance, occasional
incident.
- ~3σ — watch list. Repeated rule breaks or highly
variable output.
- Below 3σ — re-train or re-task. In this clip
Myar is in this range because she did zero deliveries and
entered the machine zone multiple times.
Why "illustrative"
Real Six-Sigma analysis requires industry-set spec
limits and a true control chart on each process variable.
Here we collapse three different signals into one score so
a supervisor can see at a glance who needs attention.
Replace the components with your own targets (cycle time
in seconds, PPE roster, walking-pace threshold) and the
numbers become directly comparable to your operational
benchmarks.
What drives the workforce score
Workforce σ is the unweighted mean of the per-worker scores.
A single low performer pulls the aggregate down sharply —
which is the point. The aggregate is meant to be read
alongside the per-worker cards, not in isolation.