Six Sigma Process Control

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Six Sigma Process Control

• Sonja Arnet
• Jason Larocco
• POMG 248
• 5/13/03

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What is Six Sigma?

• A tool box of statistical tools used to reduce
  defects in a process down to 3.4 DPMO, 99.99966
  yield
• Cpk 1.5- Process variation equals half of the
  design tolerance
• O- a symbol used for standard deviation

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Development of 6s

• 1980s- US corporations began losing market
  share to
• Japanese
• 1987- Motorola pioneered the use of Six Sigma
• Bill Smith- Father of Six Sigma
• Bob Galvin- CEO of Motorola
• MAIC Process
• 1995- General Electric
• Jack Welch, CEO of GE
• Created Six Sigma problem solving approach used
  today
• DMAIC Process

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6s Success Stories at GE

• 1998- Savings of 750 million
• 1999- Savings of 1.5 billion
• Expected savings over next decade- 7-10 billion
• Examples of Process Improvement
• GE Lighting- Decrease invoice defects by 98
• GE Medical- Decrease time for full body scan from
  3 minutes to 30 seconds
• GE Capital Mortgage- Improved rate of callers
  reaching a live person from 76 to 99
• GE Industrial Diamond- Improved ROI 400

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GEs DMAIC Process

• Define
• Measure
• Analyze
• Improve
• Control

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Define

• Identify
• Customers and Priorities
• Project
• CTQs
• Develop Team Charter
• Define The Process

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Stage Define
CTQ Tools

• Quality Function Deployment (QFD)
• Process Mapping
• Fishbone
• Pareto Chart
• Failure Modes and Effects Analysis (FMEA)

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Measure

• Select Measurement for CTQ
• Define Specification Limits (What is a defect)
• Validate Measurement System (GRR)

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Stage Measure
Validating A Measurement System

• Gage RR-
• Will show how much of your spec limit will be
  used up by the variation in your measurement
  system
• If measurement system is not valid you cannot
  correctly identify a defect
• Total GRR lt 10 is desirable, lt 30 acceptable

30 Measurement Var.
70 Process Variation
Total Spec Limit
LSL
USL
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Analyze

• Establish Process Capability (Baselining)
• Define Performance Objectives
• Identify Variation Sources

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Stage Analyze
Material
Machine
Measurement
Feed Rate
Tool wear
Spindle Speed
Coolant
Surface Finish
Environment
Method
Manpower
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Improve

• Screen Potential Causes
• Screening DoE (Taguchi)
• Discover Variable Relationships
• Regression Analysis
• Establish Operating Tolerances
• From GRR

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Stage Improve
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Stage Improve
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Stage Improve
Regression Plot
Y 1.86-1.9E-02X
Y 1.85976 - 1.91E-02X
Operating Tolerance15.01
R-Sq 99.2
2
1.5
1.4
Surface finish
1
0
100
90
80
70
60
50
40
30
20
10
0
Tool wear
27
22
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Control

• Define and Validate Measurement Systems for Xs
• Determine New Process Capability
• Implement Process Control

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Stage Control
Implementing Process Control

• Process Controls
• Documentation
• Statistical Process Controls (SPC)
• Mistake proof devices
• Data collection plans
• Audit plans
• Response plans

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References-

• Six Sigma for Electronics Design and
  Manufacturing- Sammy G. Shina, May 2002
• The Six Sigma Way- Peter S. Pande, Robert P.
  Neuman, Roland R. Cavanagh, 2000
• The Management and Control of Quality- James R.
  Evans, William M. Lindsay, 2002
• Six Sigma Producibility Analysis and Process
  Characterization- Mike J. Harry, J. Ronald
  Lawson, 1992