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Six Sigma
6s
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Dilbert
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Introduction
6? new world
s is the symbol for the standard deviation. 6s
is equivalent with 3.4 defects per million
opportunities.

• Hooving 30 m2 on 6s -level means only 1 cm2
  missed.
• 1/3.4 million part of the day equals 0.29 second
• 1/3.4 million part of the equator of the earth
  equals about 140 meter.

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Statistical background
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Statistical background
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6
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What is Six Sigma?

• Simple
• Eliminate defects
• Eliminate the opportunity to have defects
• Complex
• Vision
• Metric (Standard measuring method)
• Benchmark
• Philosofy
• Method
• Tool for
• Customer satisfaction
• Breakthrough improvements
• Continuous improvement
• Employee involvement
• Agressive goals

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Six Sigma is everywhere
Service
Design
Management
Purchase
Six Sigma Methods
Administration
Production
IT
Quality Depart.
HRM
M S
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Uniform standard
Sigma-metric
Current standard
World class
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Financially interesting
Benefits of 6s approach w.r.t. financials
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Why improvement?
Process step
Client
Inspection
Input
good products
The hidden factory
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Six Sigma
Companies implementing Six Sigma

• Motorola (1987)
• Texas Intruments en DEC (1988)
• IBM (1989)
• AlliedSignal en Kodak (1994)
• General Electric (1995)
• Whirlpool, Bombardier en Polaroid (1996)
• Sony, Citibank (1997)
• Paccar-DAF Trucks, Black Decker (1998)
• Perlos, American Express (1999)
• Ford (2000)

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Six Sigma
A scientific and practical method to achieve
improvements in a company

• Scientific
• Structured approach.
• Assuming quantitative data.
• Practical
• Emphasis on financial result.
• Start with the voice of the customer.

Show me the data
Show me the money
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Method
DMAIC
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Method
Focus on the process
Y f(X1, X2, , Xn)
Output
Inputs
Process
Caffeine f(DCM, time to extract, number of
extracts, temperature, )
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New way?
Approach to improve
Statistical problem
Praktical problem
Y f(X1, X2, , Xn)
Praktical solution
Statistical solution
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Define

• Projects may be selected according to
• A complete list of requirements of customers.
• A complete list of costs of poor quality.
• A complete list of existing problems or targets.

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Priorities
3
2
1
1.Collect data
2.Arrange the information

• 3.Give priority
• Financial benefits
• Expected throughput time of the project
• Severity of the problem

1. Requirements, 2. Costs, 3. Problems.
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Six Sigma
Characteristics involved
Y f(X1, X2, , Xn)
Critical to Quality (External) Critical to
Quality (Internal)

• Influence factors
• Process parameters
• Disturbances
• Noise variables

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Example
Coffee beans
Roast
Cool
Grind
Moisture content
Pack
Sealed coffee
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Measure
Measure

• Concrete the problem
• Establish how to measure in the process
• Investigate the demands (USL, LSL)
• Evaluate the measurement method.

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Measure
USL
4.5
4.0
Moisture
? ? ? ? ? ? ? ? ? ? ? ? ?
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Analyse
Analyse

• Study the current performance of the process
• Determine the kind of problem
• Identify the influence factors.

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Analyse
To run experiments one needs a process which is
in statistical control.
SPC
DoE
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Control chart, Cp, Cpk
Process Capability study
Identify Xs
Identify Xs
Multi-vari, Trendgraph
FMEA, Control chart
Select Xs
Select Xs
FMEA, Data
Testing- theory
Improvements
Experiment
Improve
Assure, Control loop
Control
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Analyse
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Analyse
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Analyse
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Three types of influence factors
Caffeine content of Extracted coffee
Caffeine raw coffee
Stuffed-up filter
Time to extract
Processparameter
Noise variable
Disturbance
May be used to control.
Undesirable sources of variation.
Outliers, incidents
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Improve
Improve

• Run a statistical experiment
• Determine which influence factors are really
  important
• Model the relationship with the CTQ.

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Improve
Moisture 16.57 0.023?B 0.025?G
0.0003?B?G
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Control
Control

• Implement improvements
• Use the relationship to define an optimal
  process
• Design a system to assure the improvements.

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Control
Before
s 0.19
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Organisation
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Persons
Champion

• Belongs to management
• Selects projects
• Gives priority
• Solves bottlenecks
• Is willing to change
• Has social skills
• 1 day training
• Is responsible for the BB project w.r.t. the
  organisation

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Persons
Black Belt

• Belongs to the middle management
• Is well-educated
• Project is related to daily activities
• May prioritise his work
• Enough motivation
• Willing to change
• Has good social skills

Improvement potential 50 000
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BB training
Define
Throughput time project
4 months (full time)