Download - Six Sigma PTO
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WINTRODUCTION
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W SIGMA) ;
jIS A LETTER IN THE GREEK ALPHABET
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W SIGMA) ;jIS A LETTER IN THE GREEK ALPHABET
jIS A STATISTICAL MEASUREMENT UNIT
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WHAT DOES SIGMA LEVEL MEAN?
Quality level of product
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WHAT DOES SIGMA LEVEL MEAN?
Quality level of productProcess performance
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WHAT DOES SIGMA LEVEL MEAN?
Quality level of productProcess performance
Reliability for customer
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DPMO ;DPMO ;
jMEANS DEFECTS PER MILLION
OPPORTUNITIES
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DPMO ;DPMO ;
jMEANS DEFECTS PER MILLION
OPPORTUNITIES
jIS TRANSLATED INTO A SIGMA
NUMBER
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What is Six Sigma?Is an Organization-Wide Initiative to achieve zero defectsand reduce wastes (Muda) and variations in the processes
Top Management commitment and strong reviewmechanisms are the key to the success of the Six sigmaInitiative
Trained people who are skilled in undertaking the processesand also has the skill in the selection and application ofSixsigma tools to achieve zero defects are essential in thisinitiative
During the initial deployment phases, Black belts have tospend at-least 50% of the time in the projects
This is an initiative which will lead the organization in thelong run to achieve Six Sigma levels in each of theirmanufacturing/service processes
Successful Organization wide deployment ofSix Sigma willtake a minimum of three years.
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Origin
Six Sigma initiative was first developed by Mr. BillSmith, who was working as Quality Manager atMotorola
With a strong commitment from Mr. Bob Galvin, thenCEO of Motorola, the implementation of the initiativebegan in 1986
This initiative helped Motorola win the first MalcolmBaldrige Award in 1998
Several of the major companies in the world haveadopted Six Sigma since then
Texas Instruments, ABB, GE, Nokia Mobile phones,Sony, Dupont, Polaroid, American Express and Ford
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Birds eye view of Six Sigma
Data based decision making. No AtmosphericAnalysis
Structured troubleshooting done by cross functionalteams having Process Knowledge
Project selection done by Top Management
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Six Sigma Focus RolledThroughput Yield (RTY)
Y (RTY) = f(X) = Y1x Y2xY3xY4
RTY Objective (100%)
Methodology adopted is Funneling
Big Y = Main Response for the problem
X = Cause (s) that are not controllable. Theseas also called as Intermediate Ys
Root Xs = Root Cause (s) that arecontrollable by implementing processimprovement actions
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Q
THE NORMAL DISTRIBUTION CURVE
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Q !
! !
1 2 1 x x xx
n
i
i
n
n n
....
Q6 W 4 W5 W 3 W 2 W 1W 1W 2 W 3 W 4 W 5 W 6 W
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YIELD + DEFECT = 100%
YIELD
DEFECT
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Do you accept 1 % defect?j In every hour sending 22 000 cheques into the
wrong account
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Do you accept 1 % defect?j In every hour sending 22 000 cheques into the
wrong account
j Unsafe drinking water almost 1 hour in a month
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Do you accept 1 % defect?j In every hour sending 22 000 cheques into the
wrong account
j Unsafe drinking water almost 1 hour in a month
j No electricity for 7 hours each month
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Do you accept 1 % defect?j In every hour sending 22 000 cheques into the
wrong account
j Unsafe drinking water almost 1 hour in a month
j No electricity for 7 hours each month
j In a year your heart beat stops for 32 000 times, thismeans you are 100% surely100% surely100% surely DEAD!DEAD!DEAD!
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T
Z USL T !
W
6 W 4 W5 W 3 W 2 W 1W 1W 2 W 3 W 4 W 5 W 6 W g g
How Many Standard Deviations Are There Between USL and T?
LSL USL
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0. 0.000003
6 SI
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WHAT
WE DO A
S6
SIGMA TEAM ?
We
take measurements
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WHAT
WE DO A
S6
SIGMA TEAM ?
We
take measurements
calculate Sigma Level
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WHAT
WE DO A
S6
SIGMA TEAM ?
We
take measurements
calculate Sigma Levelanalyze the measurements
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WHAT
WE DO A
S6
SIGMA TEAM ?
We
take measurements
calculate Sigma Levelanalyze the measurements
detect areas for improvement
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W
HATW
E DO AS
6S
IGMA TEAM ?We
take measurements
calculate Sigma Levelanalyze the measurements
detect areas for improvement
come up with recommendations
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W
HATW
E DO AS
6S
IGMA TEAM ?We
take measurements
calculate Sigma Levelanalyze the measurements
detect areas for improvement
come up with recommendations
implement
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WHAT WE DO AS 6 SIGMA TEAM ?
We
take measurements
calculate Sigma Levelanalyze the measurements
detect areas for improvement
come up with recommendations implement
control
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ClassificationofBlackBelt Projects
CTQ (Critical to Quality)
Scrap Reduction
Rework reduction
Variation Reduction Resolving customer complaints
CTS (Critical to Satisfaction)
No complaints from customer/user Project selected
only to enhance the performance of theproduct/service level
CTC (Critical to Cost)
Process Optimization projects
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Measure &Calculate Implement
ImproveAnalyze Control
FLOW CHART OF SIX SIGMA
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HOW THE MEASUREMENTS ARE
TAKEN?
BY A TRAINED 6 SIGMA TEAM, CALLED BLACKBELTS
WITH COOPERATION OF THE EMPLOYEE
S
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SIGMA LEVEL
S
6 SIGMA
5 SIGMA
4 SIGMA
3 SIGMA
2 SIGMA
6 SIGMA
OUR AIM IS
TO REACH 6S
IGMA LEVEL TOGETHER
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WHAT SIX SIGMA WILL DO FOR USWHAT SIX SIGMA WILL DO FOR US
HELPS IMPROVE :HELPS IMPROVE : First Pass Yield/Input OutputFirst Pass Yield/Input Output Delivery PromptnessDelivery Promptness
Cost of QualityCost of Quality
... BY REDUCING OUR :... BY REDUCING OUR : Defects Per UnitDefects Per Unit Throughput TimeThroughput Time
... WHICH SHOW UP IN OUR:... WHICH SHOW UP IN OUR:
Bottom Line ResultBottom Line Result CustomerSatisfactionCustomerSatisfaction
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W - M
1
10
1001
000
10000
100000
1000000
2 3 4 5 6
SIGMA
M
VALUES COME FROMVALUES COME FROM
SIX SIGMASIX SIGMA
TRANSFER KNOWLEDGE THROUGHTRANSFER KNOWLEDGE THROUGH- QUALITY IMPROVEMENT
- TROUBLESHOOTING
QUALITYQUALITY--COSTCOST--TIMETIME
BREAKTHROUGHBREAKTHROUGHSTRATEGYSTRATEGY
Phase 1Phase 1MeasurementsMeasurements
Phase 4Phase 4ControlControl
Phase 3Phase 3ImprovementImprovement
Phase 2Phase 2
AnalysisAnalysis
Benchmarking
AverageCompany
Best-in-Class
ppm
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TROUBLESHOOTINGTROUBLESHOOTING
SHORT TERM
THE BREAKTHROUGH STRATEGYBREAKTHROUGHBREAKTHROUGHSTRATEGYSTRATEGY
Phase 1Phase 1MeasurementsMeasurements
Phase 4Phase 4
ControlControl
Phase 3Phase 3ImprovementImprovement
Phase 2Phase 2AnalysisAnalysis
Processparameter
Productparameter
LSL
USL
Adjustmentrange
Distributionwithoutcontrollingtheprocessparameter
Distributionwithfixedprocessparameter
(reducedvariability)
Processparameter
Productparameter
LSL
USL
Adjustmentrange
Distributionwithoutcontrollingtheprocessparameter
Distributionwithfixedprocessparameter
(reducedvariability)
MEASUREMEASUREMEASURMENTS
Run 1
Run 2
Run 3
Run 4
Run 5
Run 6
Run 7
ANALYZEANALYZE
LSL TARGET USL
IMPROVEIMPROVE
CONTROLCONTROLNumber
f
ample
1 2 3 4 5 6 7 8 9 1 0 11 1 2 13 1 4 15 1 6 17 1 8 19 2 0
OKr
Bereic
OKB 1.800 1.800 1.800 1.800 1.800 1.800 1.800 1.800 1.800 1.800 1.800 1.800 1.800 1.800 1.800 1.800 1.800 1.800 1.800 1.800
OK
e Bereic
1.670 1.670 1.670 1.670 1.670 1.670 1.670 1.670 1.670 1.670 1.670 1.670 1.670 1.670 1.670 1.670 1.670 1.670 1.670 1.670
OKr
Bereic
1.170 1.170 1.170 1.170 1.170 1.170 1.170 1.170 1.170 1.170 1.170 1.170 1.170 1.170 1.170 1.170 1.170 1.170 1.170 1.170
OK
rBereic
C
1.545 1.545 1.545 1.545 1.545 1.545 1.545 1.545 1.545 1.545 1.545 1.545 1.545 1.545 1.545 1.545 1.545 1.545 1.545 1.545
OK
e Bereic
C
1.295 1.295 1.295 1.295 1.295 1.295 1.295 1.295 1.295 1.295 1.295 1.295 1.295 1.295 1.295 1.295 1.295 1.295 1.295 1.295
Gemessene
aten eff. 1.430 1.320 1.550 1.330 1.400 1.310 1.320 1.430 1.490 1.480 1.400 1.400 1.480 1.470 1.480 1.420 1.470 1.390 1.420 1.410
Tolleranz 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500
1/4Tolleranz 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125
Number
fS
mple
1.000
1.100
1.200
1.300
1.400
1.500
1.600
1.700
1.800
1 2 3 4 5 6 7 8 9 1 0 11 12 13 14 15
USL
UPCL
LPCL
LSL
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TROUBLESHOOTINGTROUBLESHOOTING
SHORT TERM
MEASUREMEASURE
MEASURMENTS
Run 1
Run 2
Run 3
Run 4
Run 5
Run 6
Run 7
We dont know what we dont know
We cant act on what we dont know
We wont know until we search
We wont search for what we dont question
We dont question what we dont measure
Hence, We just dont know...
Dr Mikel Harry
IF WE CANT EXPRESSWHAT WE KNOW IN THE FORM OF NUMBERS,IF WE CANT EXPRESSWHAT WE KNOW IN THE FORM OF NUMBERS,
WE REALLY DONT KNOW MUCH ABOUT ITWE REALLY DONT KNOW MUCH ABOUT IT
Dr Mikel Harry
LET DATA BE THE BASE TO OUR ACTIONS!LET DATA BE THE BASE TO OUR ACTIONS!
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TROUBLESHOOTINGTROUBLESHOOTING
SHORT TERM
ANALYZEANALYZE
NORMAL DISTRIBUTIONNORMAL DISTRIBUTION
POINT OF DEFLECTION
QW
CUS
S
S
UCTI
N
SUPPLI
Or
er
O r
er
recep tion
W riting
purc!
aseor
ers
Break
own of
or
erPlanningof s upplies
Plann ingof s upplies
"
ece ipt ofplanned
supplies
W riting
purc!
as e
r rOrder
OrderOrder
con firmation
Order
con firmation
NG INEERING
PURCHASE
RECEPTI
N
PROCESS APPINGPROCESS APPING
Background Information
Company XXXX Product ENGINEFactory YYYY Product ID 12345Location VSTERS Recorder B . SMITHDepartment 11 D at e A UG -12-1995
Six Sigma Analysis
No. Description Ord er D e f ec t s U n i ts D P U O TOP DPO Z1 Winding diameterWiA leg 1 2 6 3 2.0002-001-0400 2,90E-01 1 2 , 90E-01 1 1 2,90E-01 2,052 Winding diameterWiA leg 2 2 6 3 2.0002-001-0400 1,85E-01 1 1 , 85E-01 1 1 1, 85E-01 2 , 403 Winding diameterWiB leg 1 2 6 3 2.0002-001-0400 4,00E-01 1 4,00E-01 1 1 4,00E-01 1 , 754 Winding diameterWiB leg 2 2 6 3 2.0002-001-0400 1,97E-01 1 1 , 97E-01 1 1 1, 97E-01 2 , 355 Winding diameterWiC leg 1 2 6 3 2.0002-001-0400 3,94E-01 1 3 , 94E-01 1 1 3, 94E-01 1 , 776 Winding diameterWiC leg 2 2 6 3 2.0002-001-0400 2,43E-01 1 2 , 43E-01 1 1 2, 43E-01 2 , 207 Winding diameterWiD leg 1 2 6 3 2.0002-001-0400 5,00E-01 1 5,00E-01 1 1 5,00E-01 1 , 508 Winding diameterWiD leg 2 2 6 3 2.0002-001-0400 3,78E-01 1 3 , 78E-01 1 1 3, 78E-01 1 , 819 Dirt 2632.0002-001-0400 0,00E+00 1 0,00E+00 1 1 0,00E+00 6,00
10 Winding diameterWiA leg 1 2 6 3 2.0002-001-0500 4,35E-01 1 4 , 35E-01 1 1 4, 35E-01 1 , 6611 Winding diameterWiA leg 2 2 6 3 2.0002-001-0500 4,91E-01 1 4 , 91E-01 1 1 4, 91E-01 1 , 5212 Winding diameterWiB leg 1 2 6 3 2.0002-001-0500 3,42E-01 1 3 , 42E-01 1 1 3, 42E-01 1 , 9113 Winding diameterWiB leg 2 2 6 3 2.0002-001-0500 5,00E-01 1 5,00E-01 1 1 5,00E-01 1 , 5014 Dirt 2632.0002-001-0500 5,88E-02 1 5 , 88E-02 1 1 5, 88E-02 3,0615 Common spacerring thickness 2632.0004-001-0120 1,03E-01 1 1,03E-01 1 1 1,03E-01 2 , 7716 Common spacerring thickness 2632.0004-001-0120 4,08E-04 1 4,08E-04 1 1 4,08E-04 4 , 8517 Common spacerring thickness 2632.0004-001-0120 2,51E-03 1 2 , 51E-03 1 1 2, 51E-03 4 , 3118 Common spacerring thickness 2632.0004-001-0120 1,05E-1 9 1 1 ,05E-19 1 1 1,05E-19 10,5119
2021
2223
24
2526
27
2829
3031
32
33
34
35
36
37
3839
404142
4344
45
Rolled = 5 18 0, 2 5 11 2 , 1 7
COMPUTE THE SIGMACOMPUTE THE SIGMA
7 QUALITY TOOLS7 QUALITY TOOLSCharts and Graphs
Check Sheets
Pareto Charts
Cause and Effect (Ishikawa/Fishbone) Diagrams
Scatter Diagrams
Histograms
Control Charts
* EVALUATE THE PROCESS* EVALUATE THE PROCESS
* DEFINE THE PROBLEM* DEFINE THE PROBLEM
*DEFINE THE GOAL
*DEFINE THE GOAL
* PLAN FOR IMROVEMENT* PLAN FOR IMROVEMENT
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TROUBLESHOOTINGTROUBLESHOOTING
SHORT TERM
IMPROVEMENTIMPROVEMENT* SELECT VARIABLES* SELECT VARIABLES
* DIAGNOSE PERFORMANCE* DIAGNOSE PERFORMANCE
*UNDERSTAND THE PROBLEM
*UNDERSTAND THE PROBLEM
* EXECUTE IMPROVEMENTS* EXECUTE IMPROVEMENTS
DESIGN OF EXPERIMENT
A
BC
Trial A B C
1 - - -
2 + - -
3 - + -
4 + + -
5 - - +
6 + - +
7 - + +
8 + + +
+
-
+
-
+-
PERFORMANCE TOLERANCING
Processparameter
Productparameter
LSL
USL
Adjustment range
Distributionwithout controlling the
process parameter
Distributionwithfixed process parameter
(reduced variability)
Processparameter
Productparameter
LSL
USL
Adjustment range
Distributionwithout controlling the
process parameter
Distributionwithfixed process parameter
(reduced variability)
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TROUBLESHOOTINGTROUBLESHOOTING
SHORT TERM
CONTROLCONTROL
Statistical Process ControlNumber of S amp le
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
O K r o#
ereich O K#
1 .8 00 1 .8 00 1 .8 00 1 .8 00 1 .8 00 1 .8 00 1 .8 00 1 .8 00 1 .8 00 1 .8 00 1 .8 00 1 .8 00 1 .8 00 1 .8 00 1 .8 00 1 .8 00 1 .8 00 1 .8 00 1 .8 00 1 .800
O K g e#
ereich U S L 1 .6 70 1 .6 70 1 .6 70 1 .6 70 1 .6 70 1 .6 70 1 .6 70 1 .6 70 1 .6 70 1 .6 70 1 .6 70 1 .6 70 1 .6 70 1 .6 70 1 .6 70 1 .6 70 1 .6 70 1 .6 70 1 .6 70 1 .670
O K r o#
ereich LS L 1 .1 70 1 .1 70 1 .1 70 1 .1 70 1 .1 70 1 .1 70 1 .1 70 1 .1 70 1 .1 70 1 .1 70 1 .1 70 1 .1 70 1 .1 70 1 .1 70 1 .1 70 1 .1 70 1 .1 70 1 .1 70 1 .1 70 1 .170
O K g r #
ereich U P$
L 1 .5 45 1 .5 45 1 .5 45 1 .5 45 1 .5 45 1 .5 45 1 .5 45 1 .5 45 1 .5 45 1 .5 45 1 .5 45 1 .5 45 1 .5 45 1 .5 45 1 .5 45 1 .5 45 1 .5 45 1 .5 45 1 .5 45 1 .545
O K g e#
ereich L P$
L 1 .2 95 1 .2 95 1 .2 95 1 .2 95 1 .2 95 1 .2 95 1 .2 95 1 .2 95 1 .2 95 1 .2 95 1 .2 95 1 .2 95 1 .2 95 1 .2 95 1 .2 95 1 .2 95 1 .2 95 1 .2 95 1 .2 95 1 .295
Ge messene Daten ef f . 1 .4 30 1 .3 20 1 .5 50 1 .3 30 1 .4 00 1 .3 10 1 .3 20 1 .4 30 1 .4 90 1 .4 80 1 .4 00 1 .4 00 1 .4 80 1 .4 70 1 .4 80 1 .4 20 1 .4 70 1 .3 90 1 .4 20 1 .410
T olleranz 0 .5 00 0 .5 00 0 .5 00 0 .5 00 0 .5 00 0 .5 00 0 .5 00 0 .5 00 0 .5 00 0 .5 00 0 .5 00 0 .5 00 0 .5 00 0 .5 00 0 .5 00 0 .5 00 0 .5 00 0 .5 00 0 .5 00 0 .500
1 /4 Tolleranz 0 .1 25 0 .1 25 0 .1 25 0 .1 25 0 .1 25 0 .1 25 0 .1 25 0 .1 25 0 .1 25 0 .1 25 0 .1 25 0 .1 25 0 .1 25 0 .1 25 0 .1 25 0 .1 25 0 .1 25 0 .1 25 0 .1 25 0 .125
Nu m b er o f S am p le
1 . 00 0
1 . 10 0
1 . 20 0
1 . 30 0
1 . 40 0
1 . 50 0
1 . 60 0
1 . 70 0
1 . 80 0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
US L
UP$
L
LP$
L
LSL
Precontrol (Preset Control Limits)
U S L U p p e r S p e c if ic a t io n L im it L S L L o w e r S p e c i f i c a t i o n L i m i t
U P C L U p pe r P re co ntro l L im it L PC L L ow er P re co ntro l L im it
* MONITOR PROCESS AFTER IMPROVEMENT* MONITOR PROCESS AFTER IMPROVEMENT
* ENSURE CAPABILITY* ENSURE CAPABILITY
LSL TARGET USL