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History of Six Sigma - Motorola 1985-1991

Due to the high number of inquiries regarding the history of Six Sigma, the following is a historical timeline with original documentation. If you are interested in any particular document, please fill out the form under Contact Us.
Timeline Six Sigma History Timeline Documents
Date 1985 Document
Nov 1985 Motorola's Government Electronics Group, GEG, starts high volume production for FMU-139. Mario Perez-Wilson is hired by Motorola GEG, Tactical Electronics Division (TED) to implement statistical methods in the FMU-139 program. Six sigma was understood to be plus or minus 3 standard deviations within specification limits. Motorola's Six Sigma quality goal was not yet established. 1985-11-01 FMU-139.pdf
Nov 1985 Mr. Perez-Wilson implements statistical process controls at Motorola GEG, TED FMU-139 Bomb Fuze. 1985-11-22 CCL.pdf
Dec 1985 Mr. Perez-Wilson's statistical analysis concentrates on Automatic Wave Solder systems and Printed Wiring Boards (PWB) suppliers' quality due to defect analysis. 1985-12-18 CC.pdf
Dec 1985 Analysis of Wave Solder system leads to establishing control and stability on top-side temperature parameter. 1985-12-18 TST.pdf
Date 1986 Document
Jan 1986 Mr. Perez-Wilson designs Data Analysis System (DAS) software to analyze data for the FMU-139. Post Wave Solder data is analyzed just in time for corrective action by the PWB supplier. 1986-01-23 DAS.pdf
Jan 1986 Mr. Perez-Wilson's statistical analysis identifies one PWB supplier out of three, to be always under statistical control and with a low average and standard deviation. 1986-01-27 CCHARTS.pdf
Feb 1986 Poor wetting and insufficient solder detected to increase defects across all PWB suppliers. 1986-02-04 CCVendor.pdf
Feb 1986 Manufacturing embarks on Statistical Process Control (SPC) implementation. 1986-02-11 CCManuf.pdf
Feb 1986 One particular PWB type continuously exhibits non-random patterns and the best PWB supplier maintains a low defect average and standard deviation. 1986-02-17 PostWaveCC.pdf
Mar 1986 Worst PWB supplier is taken out of suppliers list. Continuous data is collected on Wave Solder parameters, flux density and pre-heat temperature for correlation. 1986-03-25 PWSCC.pdf
Apr 1986 Post Wave Solder defects control charts for Feb and March reveals that best PWB board supplier's average drow to 15, sigma to 5. 1986-04-07 PWS-CC.pdf
Apr 1986 Post Wave Solder defect Control Charts continues to perform very well (under statistical control) for best PWB supplier. 1986-04-11 PWS-CC.pdf
Apr 1986 PWS Control Charts continue to show statistical control as above 1986-04-22 PWS CC.pdf
May 1986 FMU-139 issues with rotor is analyzed statistically for contact during save position. 1986-05-11 RDA.pdf
Jun 1986 Excise Machine Capability Study is done at FMU-139, will full characterization of all parameters. 1986-06-09 CpS.pdf
Jun 1986 Statistical methods implementation plan and Machine & Process Capability Studies initiated. Mr. Perez-Wilson develops the Five-Stage M/PCpS Methodology. 1986-06-01 FMU-139.pdf
Jul 1986 All Machines and Processes undergo Machine & Process Capability Studies, following the characterization approach of M/PCpS.  
Sep 1986 Mr. Perez-Wilson continues further exploratory experimentation at Wave Solder system. 1986-09-09 BSS.pdf
Sep 1986 Mr. Perez-Wilson designs Likert scale and Concordance test analysis to prove repeatability of solder deposition inspection criteria. 1986-09-09 Likert.pdf
Sep 1986 Mr. Perez-Wilson starts full definition of all independent variables for Wave Solder system. 1986-09-09 WS VAR.pdf
Oct 1986 Lock Block Terminal Inserter machine capability study is conducted following the M/PCpS methodology in the FZU-48 Bomb Fuze Initiator. 1986-10-08 LBTI MCS.pdf
Nov 1986 Mr. Perez-Wilson develops the plan for Machine/Process Capability Studies for all machines, tools, gauges and entire process of the FZU-48 Bomb Fuze Initiator. 1986-11-01 FZU48 MPCS.pdf
Dec 1986 Mr. Perez-Wilson defines the schedule and plan for conducting Machine/Process Capability Studies to include, machines, equipment, tooling, gauges and test equipment, and defines the short term versus the long term capability studies. The studies will be done at four different stages. 1.- Repeatability prior to pilot run. 2.- Short term during pilot run. 3.- Short term during first-article. 4.- Long term during full scale production. 1986-12-12 MPCS-FZU48.pdf
Date 1987 Document
Jan 1987 Motorola Launches the Six Sigma Quality Goal and the Total Customer Satisfaction (TCS) Program on Jan 15, 1987. Memo from Bob Galvin to all employees. 1987-01-15 Six Sigma.pdf
Jan 1987 Motorola Launches the Six Sigma Challenge on Jan 15, 1987. Motorola's "Our Six Sigma Challenge" document, issue 1, 2 and 3 is sent to all employees. Motorola defines Six Sigma as plus or minus six standard deviations within specification limits, in conflict with the current understanding that six sigma is plus or minus three. 1987-01-6SChallenge.pdf
1987-01-15 SS ISSUE2.pdf
Mar 1987 Mr. Perez-Wilson defines the SPC Team to plan, control, implement and report for all control charts, machine and process capability studies and experimental designs in FMU-139 and FZU-48 programs. Also, established standard operating procedures (SOP) for SPC and established SPC audit system. 1987-03-26 SPCon139-48.pdf
Jan 1987 Jul 1987 All Machine & Process Capability Studies on FZU-48 are completed and documented.  
Jun 1987 Mr. Perez-Wilson conducts the first experiment for Cover Opening O-Ring problem. Five consecutive weeks of experimentation is done to correct the problem. 1987-06-26 FZU-EXP.pdf
Jul 1987 Mr. Perez-Wilson issues a new inspection procedure and 100% inspection for new design of FZU-48 units. 1987-07-23 MII-CO.pdf
Jul 1987 Motorola Semiconductor prepares a kit for understanding the Six Sigma goals. By July 1987, still no training is available on how to achieve Six Sigma. 1987-07-23 SPS.pdf
Oct 1987 Mr. Perez-Wilson conducts Machine/Process Capability Study during full scale production and reports finding on Spring Clip Inserted far exceeding Motorola's Six Sigma goal. 1987-10-01 MPCS Inserted.pdf
Oct 1987 Mr. Perez-Wilson shows results of Machine/Process Capability Studies for FZU-48 in most cases exceeding Six Sigma, and presents schedule and plan for studies into full scale production. 1987-10-05 MPCS.pdf
Nov 1987 Mario Perez-Wilson joins the Staff of Carlos Genardini, GM-VP of Motorola Discrete OSCPD Semiconductor - and gets promoted to Division Engineering Manager for the Dept. of Statistical Methods to disseminate the M/PCpS Methodology to achieve and sustain Six Sigma.  
Date 1988 Document
Jan 1988 Mr. Perez-Wilson publishes an article describing the improvements at the FZU-48 fuze initiator of the FMU-139 bomb fuze "exceeding Motorola's Six Sigma design objective", from the implementation of his methodology of Machine/Process Capability Studies. 1988-01-21-Round-up.pdf
Jan 1988 Semiconductor Sector of Motorola starts to implement the M/PCpS Methodology for Six Sigma with excellent success. 1988-01-01 JOB DESC.pdf
Mar 1988 Motorola designs and delivers the first training on Six Sigma - Understanding Six Sigma - one year and three months after its kick-off. The training is mostly for non-manufacturing. 1988-03-21 USS.pdf
Apr 1988 Gauge Capability Studies initiated under the M/PCpS methodology for all gauges. 1988-04-06 GRR.pdf
Apr 1988 The M/PCpS methodology is reviewed and approved as "comprehensive 'how to do it' instructions ... for conducting process capability studies worldwide." 1988-04-28 DAVE GILBERT.pdf
May 1988 Mr. Perez-Wilson recognized as "exceptionally well qualified in the field of applied statistics" to teach M/PCpS for the achievement of Six Sigma goals to the offshore facilities of Motorola Semiconductor. 1988-05-27 ED BEDELL.pdf
May 1988 Mr. Perez-Wilson is recognized for his leadership by Jim Norlin, VP General Manager Motorola Semiconductor Sector, for his Six Sigma Implementation Plan, setting the expectation for all divisions. 1988-05-27 SSSPD.pdf
Nov 1988 Motorola wins the Malcolm Baldridge National Quality Award. 1988-11-01 Malcolm.pdf
Nov 1988 Mr. Perez-Wilson provides review of M/PCpS studies in Seremban, Malaysia and starts teaching in Kuala Lumpur facility. 1988-11-01 SEREMBAN.pdf
Nov 1988 Motorola Kuala Lumpur invites Mr. Perez-Wilson to teach and deploy M/PCpS for Six Sigma. 1988-11-21 DEVADASAN.pdf
Nov 1988 Ed Bedell recommends M/PCpS to all Motorola offshore sites. 1988-11-21 ED BEDELL.pdf
Nov 1988 Motorola Asia-Pacific facilities request to participate in M/PCpS implementation. 1988-11-22 GLENN KIRK.pdf
Nov 1988 Motorola Kuala Lumpur facility requests additional training and assistance from Mr. Perez-Wilson. 1988-11-24 KLM CLASS.pdf
Nov 1988 Motorola Asia-Pacific shows additional interest in M/PCpS. 1988-11-25 KLCHEAH.pdf
Dec 1988 Carsem (M) Bhd. Sdm. in Ipoh, Malaysia is the first company outside Motorola to be trained in Six Sigma by Mario Perez-Wilson. 1988-12-02 CARSEM.pdf
Dec 1988 At Motorola Semiconductor US, M/PCpS Notebooks are designed for all M/PCpS Teams to document completed studies and projects. 1988-12-06 MPCPS.pdf
Date 1989 Document
Apr 1989 Lockheed Missiles and Space Co. requests Mr. Perez-Wilson for a meeting and tour of Motorola Semiconductor to witness success of implementation. 1989-04-21 LOCKHEED.pdf
May 1989 Ford's Quality Operating System Review refers to Mr. Perez-Wilson's presentation as "the best presentation … top of over 170 QOS presentations to Ford … and reflective of a Six Sigma organization". 1989-05-04 FORD BEST.pdf
May 1989 Mr. Perez-Wilson presents Six Sigma Roadmap for Small Signal to representatives of DESC. Navy Weapons Support Center, USAF Space Division and NASA visiting Motorola. 1989-05-15 MILITARY.pdf
Jun 1989 US Patent Office issues Certificate of Copyright to Mr. Perez-Wilson on Machine/Process Capability Study effective Nov 30, 1988. 1989-06-20 MPCPS COPYRIGHT.pdf
Jul 1989 The function, responsibilities and position for Statistical Method Engineers, SME's Site Coordinator (first black belts) are defined by Mr. Perez-Wilson by job description. 1989-07-05 SPC ENG.pdf
Jul 1989 Jim Cavitt endorses Mr. Perez-Wilson's course on process characterization to all E.M.O. 1989-07-31 JIM CAVITT.pdf
Aug 1989 Motorola Hong Kong embarks on utilizing the M/PCpS methodology for Six Sigma. 1989-08-22 KY HAN MPCPS.pdf
Aug 1989 M/PCpS Studies becomes the standard for characterizing processes. 1989-08-28 KY HAN.pdf
Sep 1989 John Sumilas, IBM Director of Product Program Management, requests Motorola to present Six Sigma at IBM East Fishkill facility. Motorola sends Mr. Perez-Wilson to present Six Sigma implementation in semiconductor fabrication. 1989-09-08 IBM PRES.pdf
Sep 1989 Mr. Perez-Wilson presents M/PCpS to Motorola Mexico facility. 1989-09-11 MEXICO.pdf
Sep 1989 The Book entitled "Machine/Process Capability Study" the methodology for optimizing machines and processes to meet the Six Sigma Challenge at Motorola was submitted to Motorola "Silver Quilt" Incentive Award Program for Technical Publications. 1989-09-14 Silver Quilt.pdf
Oct 1989 John Parisi, from IBM, formally thanks Mr. Perez-Wilson for the "Excellent Six Sigma presentation". 1989-10-05 IBM.pdf
Oct 1989 Gary Tooker, President and Chief Operating Officer of Motorola, visits Semiconductor is very impressed with how the M/PCpS methodology is used for communication between and within facilities (fabs) about machines, process, tooling, etc., and the involvement of everyone in the organization. 1989-10-18 TOOKER.pdf
Oct 1989 Motorola Mexico standardizes the M/PCpS methodology for Six Sigma. 1989-10-31 MEXICO.pdf
Nov 1989 Mary Kennedy from Motorola Training and Education Center, MTEC, (later called Motorola University) shows her admiration for the Process Characterization Methodology of M/PCpS and its success in Motorola. 1989-11-13 MARY KENNEDY.pdf
Date 1990 Document
Jan 1990 All facilities in Motorola Asia-Pacific are standardized to the M/PCpS methodology with the active members from the Motorola Center of Excellence, MCOEs. Regional Champions are created and are responsible for M/PCpS implementation. They must take an active role in every study and must use the M/PCpS Methodology. The word Champions becomes associated with Six Sigma deployment. 1990-01-11 MCOE MPCPS.pdf
Jan 1990 Motorola Malaysia requests Mr. Perez-Wilson to teach at two facilities in Seremban, Malaysia and train two statistical method engineers, SME's. 1990-01-30 ASIA SUPPORT.pdf
Feb 1990 M/PCpS Training plan for MCOE's in Malaysia. 1990-02-05 MPCPS MCOE.pdf
Feb 1990 Mr. Perez-Wilson presents the M/PCpS Methodology to achieve Six Sigma to the Allied Signal Management Team. 1990-02-06 ALLIEDSIGNAL.pdf
Feb 1990 Motorola Mexico requests M/PCpS training for GM-VP and their management staff. 1990-02-13 MEXICO.pdf
Feb 1990 Training to three SME's site coordinators in Kuala Lumpur. 1990-02-16 SME's.pdf
Feb 1990 Mexico GM Staff undergoes three full days on M/PCpS training for executives. 1990-02-19 Mexico Class.pdf
Feb 1990 Management of Burr Brown requests to attend a presentation on the Malcolm Baldridge Award, and the implementation of Statistical Methods and Six Sigma in Motorola Semiconductor. Mr. Perez-Wilson is selected to make the Six Sigma presentation. 1990-02-22 BURR BROWN.pdf
Apr 1990 Eduardo Bustamante becomes the SME for Mexico and undergoes 6 months of training under Mr. Perez-Wilson. 1990-04-20 SPC Coord.pdf
May 1990 Progress report of M/PCpS improvement projects: PH3 Emitter, PNP Emitter, SiAl Front Metal, Die Attach, RFPM Wire Bond, RFpm Solder Print Automation, RFPM RTC IR Furnace, Case 77 Wire Bond, SOT-23 Final Tester, Daichi Mold/GP System, Fujiwa Mold, Wire Bond Delvotec, LCHPGA Wave Solder, Technics Autoplating, Au Wire Bonder, JCSP Marker, Wave Solder, Solder Seal, Ag Paste Die Bonder, Ais Pad Printing, Al Wire Bonder, STATSym Burn-in Oven. 1990-05-23 MPCPS.pdf
Jun 1990 Burr Brown, in Tucson, Arizona is the second company trained in Six Sigma on June 1990. Mike Paugh, Director of Quality Assurance, invited Mr. Perez-Wilson to their company. When Burr Brown was trained, a Nitride Chemical Vapor Deposition (CVD) process was characterized as part of the training.  
Jun 1990 Allied Signal, Kansas City Division, is the third company trained in Six Sigma on June 1990, by Mario Perez-Wilson. The top leadership management was trained first, including: Kent Theoni - Dir. Mfg. Ops., Chester Thompson - Dir of QA, Burris Wilson - Dir Test Equipment, Pete Black - Prog. Mgr., Maceo Gray - Prog. Mgr., Kathy Borhani - Dept. Head Eng'rg, James Wyckoff - Project Statistician, Charlie Kircher - Dir ES&H, Dennis Cummings - Dir Eng & Info Sys., Bob Durbin - Mgr. Program Mgmt., John Morrison - VP Operations, Bill Hoppen - Dir. Opr, Bob Schmidt - Dir Program Mgmt., Donald Leoffelholz - Dir Purchasing, ...

Over 1,400 people trained.

Jun 1990 All Tech, in Albuquerque is trained in Six Sigma and invites a number of employees from Sandia National Laboratory to participate.  
Jul 1990 Sandia National Laboratory in Albuquerque requests training by Mr. Perez-Wilson in Six Sigma.  
Aug 1990 Stephen Zinkgraf, Manager Applied Statistical Engineering in Motorola Seguin, states, "I am planning to teach a course centered around Mario's book, which I find to be excellent." 1990-08-07 Zinkgraf.pdf
Oct 1990 Motorola reemphasizes that M/PCpS is the methodology for Six Sigma. 1990-10-01 MPCPS.pdf
Oct 1990 Motorola SPC Peer review finds "We were particularly impressed with the structure which has the SPC coordinator reporting to the division manager, the extensive resources devoted to SPC on a worldwide basis, the consistency of the [M/PCpS] methodology worldwide. 1990-10-22 SPC PEER.pdf
Nov 1990 "the M/PCpS Methodology [is viewed] as a systematic approach towards achieving six sigma." 1990-11-14 TEAMS.pdf
Nov 1990 M/PCpS monthly progress review becomes an ongoing approach to improvement projects. 1990-11-21 MPCPS MONTHLY.pdf
Dec 1990 Motorola Korea submits their M/PCpS Plan for 1991. 1990-12-17 Korea.pdf
Date 1991 Document
Feb 1991 CC Shue, SME for Kuala Lumpur writes an article about the implementation of M/PCpS in Motorola. 1991-02-20 SHUE PAPER.pdf
Mar 1991 Four characterization studies being done on Wire Bonders: Foton 8030-Silver Paste, Foton 8030A Preform, ESEC 2004-Preform, ESEC 2005-Epoxy. 1991-03-03 MPCPS DIEBONDER.pdf
Mar 1991 Mr. Perez-Wilson takes a leave of absence from Motorola. 1991-03-04 MPW LEAVE.pdf
Mar 1991 Motorola Taipei embarks on M/PCpS. 1991-03-04 MPCPS TAIWAN.pdf
Mar 1991 First time that a Post uses the term "SME" in communication about the statistical methods engineers trained to be "black belts" in Motorola. 1991-03-05 SME.pdf
Mar 1991 SME's for sites:Guad-Eduardo Bustamante, KLM-Baharom Kasim, C.C. Shue, METL-Kevin Chaio, J.J. Lin, MKL-C.H.Suh, A.S. Suk, MPI-Al Calicdan, Ronnie Manubay, SBN-Hassan Endan, Norma Mohamad, US-Adi Bhote, Orlando Colon and Lisa Custer. 1991-03-06 BRYAN-HUY PHAN.pdf
Mar 1991 Post to all Team Champions. First time the term "Champions" is used for Six Sigma and is made in reference to the team mentors of M/PCpS characterization studies. 1991-03-06 MPCPS UPDATE.pdf
Mar 1991 Report of outstanding achievement accomplished by M/PCpS teams and their studies. 1991-03-07 MPCPS REPORT.pdf
Mar 1991 March M/PCpS review of Back-End M/PCpS Studies. 1991-03-18 MCOE REVIEW.pdf
Mar 1991 The First SME conference in Seoul, Korea is organized for May 27-31, 1991 to present progress of all M/PCpS studies and improvement projects coordinated by Motorola's SMEs. The SMEs present the improvements from the implementation of the Five-Stage M/PCpS Methodology in the achievement of Six Sigma. 1991-04-04 SMEConf.pdf
May 1991 The First SME conference is Seoul, Korea takes place on May 27-31, 1991 where the Statistical Methods Engineers present all the M/PCpS Studies and improvement projects. The SMEs are the first "black belts" in Motorola. 1991-05-27 SMEs.pdf
Sep 1991 Mr. Perez-Wilson resigns from his position at Motorola to work full time at his consulting firm Advanced Systems Consultants, to disseminate M/PCpS, Six Sigma and the application of statistical methods in industry.  
Sep 1991 Article written by Motorola about the implementation of the Five-Stage M/PCpS methodology for process characterization, optimization and control. Improvements are on the nature of "... teams who worked on yield loss, showed yield loss improvements of more than 90 percent. Teams who worked on mean time between assists (MTBA) improved the MTBA by 10 fold and those who worked on process capability, improved the Cpk value from below 1 to above 2 [Six Sigma]." 1991-09-01 MPCPS ARTICLE.pdf
Oct 1991
Mr. Perez-Wilson, Principal Consultant for Advanced Systems Consultants, offers consulting and training to a number of Fortune 500 companies in the application of statistical methods and Six Sigma. ASC becomes the first consulting firm to offer Six Sigma. Clients-List.pdf
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