Introduction of Six Sigma.pptx
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Introduction of Six Sigma.pptx
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BeltonConfidential:
FortrainingonlyIntroductionofSixSigmaBeltonGroupRexWongBeltonConfidential:
FortrainingonlyScopeofModulenWhatisSixSigmanWhytheneedforSixSigmanHowtoapplySixSigmaBeltonConfidential:
FortrainingonlyWhatisSixSigma?
nSixSigmaisacomprehensiveandflexiblesystemforachieving,sustainingandmaximizingbusinesssuccess.Itisuniquelydrivenbycloseunderstandingofcustomerneeds,disciplineduseoffacts,dataandstatisticalanalysis,withdiligentattentiontomanaging,improvingandreinventingbusinessprocesses.PeterSPande,RobertPNeuman,RolandRCavanaghTheSixSigmaWay(McGrawHill,2000)BeltonConfidential:
FortrainingonlySixSigmaIsThreeThingsxAstatisticalmeasurementyAbusinessstrategyzAphilosophyBeltonConfidential:
Fortrainingonly1)SixSigmaAStatisticalMeasurementnItprovidesaquantitativeperformanceassessmentofourproducts,servicesandprocesses.nItallowsforcomparisonsagainstothersimilarordissimilarproducts,servicesandprocesses.nItprovidesfeedbackonhowfaraheadorbehindweare.SixSigmahelpstoestablishourcourseandtogaugeourpaceintheracefortotalcustomersatisfaction.BeltonConfidential:
FortrainingonlySixSigmaAbusinessstrategyImprovedSigma-RatingofProcessImprovedProductorProcessQualityReducedCostofOperationsGreaterCustomerSatisfactionBeltonConfidential:
FortrainingonlyCostOfPoorQuality(COPQ)TraditionalQualityCosts(tangible)LostOpportunityHiddenFactoryAdditionalCostsofPoorQuality(intangible)(Difficultorimpossibletomeasure)COPQisafunctionofSigmaCapabilityInspectionWarrantyScrapReworkRejectsMoreSetupsExpeditingCostsLostsalesLateDeliveryLostCustomerLoyaltyExcessInventoryLongCycle-TimesEngineeringChangeOrdersBeltonConfidential:
FortrainingonlyCostOfPoorQuality(COPQ)ProfitTotalCosttoManufactureandDeliverProductsProfitTheoreticalCostsCostofPoorQualityCOPQPriceErosionTheoreticalCostsCostofPoorQualityCOPQProfitTheoreticalCostsCOPQBeltonConfidential:
Fortrainingonly3)SixSigmaAphilosophynSixSigmaisaboutworkingsmarter,notharder.nDiscoverandneutralizeharmfulsourcesofvariationnMistakesarereduced(oreliminated)nImprovedprocesscapabilitynSigmaratinggoesupBeltonConfidential:
FortrainingonlyQualityBreakthroughTimeRejectRateHistoricalLevel(0)NaturalVariationunder0(30)SpecialVariationOptimumLevel
(1)NaturalVariationunder1(31)BeltonConfidential:
FortrainingonlyWhyneedsofSixSigma?
nThegoalofSixSigmaisnottoachievesixsigmalevelsofquality(i.e.3.4dpmo).6s6s=/DefectsSixSigmaisaboutimprovingprofitability;improvedqualityandefficiencyareimmediateby-products.BeltonConfidential:
FortrainingonlySixSigmaaggressivegoalSigmaisastatisticalunitofmeasurethatreflectsprocesscapability.Thesigmascaleofmeasureisperfectlycorrelatedtosuchcharacteristicsasdefects-per-unit,parts-permilliondefective,andtheprobabilityofafailure/error.2308,537366,80746,210523363.4PPMProcessCapabilityDefectsperMillionOpp.BeltonConfidential:
FortrainingonlySixSigmaProcessmmPointofInflection1ssTUSLp(d)123456s3ssThisisa6SigmaProcessBeltonConfidential:
FortrainingonlyBenefitofSixSigmanCostreductionnProductivityimprovementnMarket-sharegrowthnCustomerretentionnCycle-timereductionnDefectreductionnCulturechangenProduct/servicedevelopmentProfitsBeltonConfidential:
FortrainingonlyCustomersNeedsInternalMetricsDeliveryPriceQualityCustomerSupplierNeedCycleTimeCostDefectsDoBeltonConfidential:
FortrainingonlyHowtoapplySixSigma?
nUnlikeconventionalimprovementprogramswhichfocusesonimprovingthedefectsonthe“output”,SixSigmafocusesonthe“process”thatcreatesoreliminatesthedefects.nSixSigmaseekstoreducevariabilityinaprocessbymeansofasystematicapproachcalledtheBreakthroughStrategy.ProcessInputOutputBeltonConfidential:
FortrainingonlySixSigmaapproachIdentifytheCustomersNeedCenteraroundtheTargetReduceVariationReduceDefectsBeltonConfidential:
FortrainingonlyFocusofSixSigma?
ProcessInputOutputTheoutput(Y)isperceivedasafunctionoftheinput(X).InputtoProcessOutputofProcessX1,XkYCausesEffectTobeControlledTobeMonitoredKeyProcessInputVariablesKeyProcessOutputVariable(KPIVs)(KPOV)BeltonConfidential:
FortrainingonlyBreakthroughStrategyBreakthroughCharacterizationOptimizationMeasureAnalyzeImproveControlDefineRealizeBeltonConfidential:
FortrainingonlyDefinenTheDefinephasesetsthestageforasuccessfulSixSigmaprojectbyaddressingthefollowingquestions:
Whatistheproblemofourfocus?
Whatsourgoal?
Andbywhen?
Whosthecustomerimpacted?
WhataretheCTXsin-concern?
Whatstheprocessunderinvestigation?
BeltonConfidential:
FortrainingonlyProjectDefinitionnImprovetimetomarketforallproductsnLeadtheindustryinkeytechnologiesnCreateworld-classmanufacturingprocessesnDevelopstrategicsupplierrelationshipsnProvidebest-in-classproductandprocessqualitynDevelopstrategicrelationshipswithkeycustomersnBecomeanemployerofchoiceBeltonConfidential:
FortrainingonlyBaselineMetricDatanBaselineTheaveragelong-termdefectlevelofaprocesswhenallinputvariablesintheprocessarerunninginanunconstrainedfashion.nEntitlementThebest-caseshort-termdefectlevelofaprocesswhenallinputvariablesintheprocessarecenteredandin-control.nBenchmarkThedefectleveloftheprocessdeemedbycomparisontobethebestprocesspossible.eg:
bestWinBenchnumbersBeltonConfidential:
FortrainingonlyBreakthroughImprovementTimeRejectRateBaselineNID(0,0)NaturalVariation(30)SpecialVariationGoalNID(1,1)NaturalVariation(31)EntitlementOpportunityforImprovement()0.7BeltonConfidential:
FortrainingonlyCostofQualityHardSavingsPotentialSavingsSoftSavingsInternalFailureCostsExternalFailureCostsScrapCosttoCustomerReworkWarrantyCostSupplierScrap&ReworkReturnedMaterialAppraisalCostsPreventionCostsInspectionQualityPlanningTestingProcessPlanningQualityAuditsProcessControlInitial&MaintenanceCostsofTrainingTest&InspectionEquipmentOpportunityCostsBeltonConfidential:
FortrainingonlyMeasurelTheMeasurephaseservestovalidateorrefinetheproblem,andtobeginthesearchforrootcauses.Itaddressesthefocusandextentoftheproblem,basedonmeasuresoftheprocess,thekeydatarequiredtonarrowtheproblemtoitsmajorfactorsorvitalfewrootcauses.BeltonConfidential:
FortrainingonlyCapabilityAnalysisConventionalMetricsnRejectRateninpercent(e.g.7.4%)ninratio(e.g.0.074)ninpartspermillion(e.g.74,000DPPM)nYieldninfirst-timeyieldninfinalyieldBeltonConfidential:
FortrainingonlyCapabilityAnalysisCapabilityAnalysisConventionalMetricsSixSigmaMetricsRejectrateInprecent(eg,7.4%)IndefectsperUnit(DPU)InRatio(eg,.074)Indefectspermillionopportunities(DPMO)Inpartspermillion(eg,74,000dppm)InthroughputyieldYieldInfirst-timeyieldInrolledthroughputyieldInfinalyieldInnormalizedyieldBeltonConfidential:
FortrainingonlyDefectperunit(DPU)nDefectsPerUnit:
Theaveragenumberofdefectsperunitproduced.DefectRate=#Defects/#Units=7/5=1.4dpu123451.ArmHeightx2.Armthicknessx3.BoreholeDia4.SwgaeholeDiaxx5.Roughness6.Teardropprofilexx7.Roll8.PitchxTotalDefectsperDisc31210ArmBeltonConfidential:
FortrainingonlyDefectsPerMillionOpportunities(DPMO)nOpportunities:
Thenumberofpossibilitiesfordefectcreationinanyunitofproductprocessorsequenceofprocesses.1.ArmHeight2.Armthickness3.BoreholeDia4.SwgaeholeDia5.Roughness6.Teardropprofile7.Roll8.PitchOpportunitiesperUnit=8NumberofOpportunities=OpportunitiesperUnitNumberofUnits=85=40DefectRate=#Defects/#Opportunities=(7/40)106=175,000dpmoBeltonConfidential:
FortrainingonlyDPMOvsSigmaCapability0.023.42336,21066,811308,770697,672-100,000200,000300,000400,000500,000600,000700,000800,00001234567SigmaCapabilityDefectsPerMillionOpportunityBeltonConfidential:
FortrainingonlyFirst-timeyield(Yft)nFirst-TimeYieldisthenumberofunitsthatpassaparticularinspection,comparedwiththetotalnumberofunitsthatpassthroughthatpointintheprocess.Process968Accept32RejectFirst-TimeYield,Yft=968/1000=0.9681,000InputBeltonConfidential:
FortrainingonlyThroughputyield(Ytp)nThroughputYieldistheprobabilitythataunitofproductorservicewillpassthroughagivenprocesssteperror-free.nThroughputYield,Ytp=eDPUProcess968Accept32Reject1,000Input(40Defects)ThroughputYield,Ytp=e-(40/1000)=0.961BeltonConfidential:
FortrainingonlyFinalYield(Yf)800ShipProcessA1,000Input50ScrapProcessB950Input25ScrapProcessC925Input125ScrapFinalYield,Yf=QuantityShipped/QuantityBuilt=800/1,000=0.80Ashortcomingoffinalyieldisthatitfailstoconsiderthe“hiddenfactory”orrework.HiddenFactory:
adhocsystemsandprocessessetuptocorrecterrorsmadeduringthemainstreamprocess.BeltonConfidential:
FortrainingonlyRolledThroughputYield(Yrp)RolledThroughputYield=Ytp(A)Ytp(B)Ytp(C)=0.74080.63930.5824=0.2758675ShipProcessA1,000Input50ScrapRework200150ProcessB800Input(950)25ScrapRework300275ProcessC650Input(925)125ScrapRework250125Defects=300Ytp(A)=e300/1,000=0.7408Defects=425Ytp(B)=e425/950=0.6393Defects=500Ytp(C)=e500/925=0.5824Defects=300BeltonConfidential:
FortrainingonlyRolledThroughputYield(Yrp)Therolledthroughputyieldistheprobabilitythataunitofproductorserviceisabletopassthroughtheentireprocessdefect-free.Itisafunctionofthedefectrate,andhenceprovidesabetterestimateoftheamountofreworkrequired.RolledthroughputyieldcanbeimprovedbyhavinghigherthroughputyieldsateachprocessstepreducingthenumberofprocessstepsBeltonConfidential:
FortrainingonlySigmaValueSigmaValue(Z-Score):
nThesigmavalueisderivedfromtheprobabilityofadefectinaprocessandi
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