Six Sigma Concept

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Six Sigma Concept
2
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• ???????????????????????? Six Sigma
• ??????????? Six Sigma
• ?????????????????????? Six Sigma
• ?????????????????????????????????????? ???????? 6

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???????????????????? Six Sigma--?????????

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• ?????????????? ?????? ???????????????? ??????
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  ?
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  ??????????

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???????????????????? Six Sigma--????????

• ??????? Six Sigma
• ????????????????
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• ??????????????????? ???????????????????????
• ??????????????????????? ??????????????????????????
  ??????????????????
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??????????? Six Sigma
?????????????????????????
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??????????? Six Sigma

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Section 1 Six Sigma An Overview
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What is Sigma?
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???????? Sigma (s)

• Sigma (s) ???
• ??????????????? 18
• ???????????????????????????????????? (Standard
  Deviation)
• ?????????????????????????????

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?????? ??? ???????????????? ??? ??????
m
??????????????????????? (s) ??????????????????????
??????????? (m)
USL
LSL
s
s
s
????????????????????? (LSL) ???????????????????
(USL) ???????????????????? (T)
????????? (m) ??????????????????? (s)
T
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Where Does Industry Stand?

IRS - Tax Advice
(phone-in)
(140,000 PPM)
Restaurant Bills
Doctor Prescription Writing
Payroll Processing

Order Write-up

Journal Vouchers
Wire Transfers
Airline Baggage Handling
Purchased Material
Lot Reject Rate
Best-in-Class
Average
Domestic Airline Flight
Company
Fatality Rate
(0.43 PPM)
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Sigma Scale of Measure
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???????? Six Sigma (6s)

• Six Sigma (6s) ????
• ?????????? World Class Company
• ?????? ??????????????????????????
  (Breakthrough)
• ?????????????
• ?????????????????
• ??????????????????????????????????????
• ?????????????????????????????????????????????????

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????? ?????? ?????? ???????????

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• ??????????????????????? ??????????????????????
  
• ?????????? ??? ????????????????????????????

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Six Sigma ?????????????????????
Sigma is a statistical unit of measure that
reflects process capability. The sigma scale of
measure is perfectly correlated to such
characteristics as defects-per-unit,
parts-per-million defective, and the probability
of a failure/error.
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Six Sigma ?????????????????
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Section 1 Six Sigma An Overview
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?????????? Six Sigma

• Started on 1960s, a number of big companies
  were toying with the idea of Zero Defect (ZD).
  But the ideas didnt go very far and limited to
  motivational slogans and pep talks.
• On 1980s, giant companies spearheaded again the
  comeback of ZD philosophy. They are now more
  serious on producing defect free products.
• For instant, Xerox with Leadership Through
  Quality, Intel with PDQ2, HP with TQC, IBM
  with Excellent in Execution etc..
• Motorola didnt want to miss the pack by
  establishing 6-Sigma program on 1987. The idea
  was first discovered by Mikel Harry, one of
  Motorola's finest employees from Government
  Electronics Group.
• By giving itself 5 years time limit to achieved
  from 3 to 6-Sigma, Motorola has spent merely 20
  million dollar in its first year alone.
  Motorola's investment paid off and proved that ZD
  was achievable.
• On the following years, Mikel Hurley left
  Motorola and set up his own company known as Six
  Sigma Academy, USA.

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??????????????? Six Sigma

• Motorola
• Texas Instruments
• ABB
• Allied Signal
• General Electric
• Seagate Technology

• DuPont
• Sony
• Kodak
• Toshiba
• Lockheed Martin
• Other

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Section 2 Six Sigma Process
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Process Variation
Process
Inputs
Output

• All businesses consist of interconnected
  processes
• Variation exist in all processes
• Understanding and reducing process variability
  in the key to improve customer satisfaction and
  reducing losses

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Focus of Six Sigma
To get results, should we focus our behavior on
the Y or X?

• X1 . . . XN
• Independent
• Input-Process
• Cause
• Problem
• Control

If we are so good at X, why do we constantly test
and inspect Y?

Focus on X rather than Y, as done historically
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Process Output Variation
s
m measurement of location s measurement of
variability
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Process Sigma Level
Definition The number of standard deviation
that can be fitted into the space between the
process center and the nearest specification
limits
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6 Sigma Process
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What does a 6 sigma process look like ?
m
Average Deviation from Mean
1s
p(d)
1 2 3 4 5 6
s
T
USL
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Six Sigma - Practical Meaning
99.99966 Good (6 Sigma)
99 Good (3.8 Sigma)
20,000 lost articles of mail per hour Unsafe
drinking water for almost 15 minutes each
day 5,000 incorrect surgical operations per
week Two short or long landings at most major
airports each day 200,000 wrong drug
prescriptions each year No electricity for
almost seven hours each month
Seven articles lost per hour One unsafe minute
every seven months 1.7 incorrect operations per
week One short or long landing every five
years 68 wrong prescriptions per year One hour
without electricity every 34 years
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6 Sigma - Aggressive Goal
Sigma is a statistical unit of measure that
reflects process capability. The sigma scale of
measure is perfectly correlated to such
characteristics as defects-per-unit,
parts-per-million defective, and the probability
of a failure/error.
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??????????? Six Sigma
?????????????????????????
??????????????
????????????????????

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Critical to...
- Price - Quality - Delivery
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???????????????????????????????

• Product
• CTQ Critical to Quality
• CTD Critical to Delivery
• CTP Critical to Price

????????????????????
Delivery ?????????
Quality ??????
Price/Value ????/??????
Defects ??????????
Cost ??????
Cycle Time ????????????

• Processes
• CTP1 Critical to Process 1
• CTP2 Critical to Process 2
• CTP3 Critical to Process 3

?????????????????
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??????? ??? Six Sigma
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Whats the Strategy
Know whats important to the Customer Reduce
defects Center around target Reduce Variation
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Section 3 The DMAIC Approach
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??????????????????

• ????????? (Management)
• ????????? (Champion)
• ?????????? (Black Belt)
• ????????? (Green Belt)
• ??????????? (Member)
• ?????????????? (Process Owner)
• ???????? ?????????? (Master Black Belt)

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??????????????????

• ????????????????? (Management)
• ?????????????????????????????????
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  ????????????????????????
• ??????????????????????????????? ??????

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??????????????????

• ????????????????? (Champion)
• ??????????????????????????????
• ???????????????????????? ???????????????????

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??????????????????

• ????????????????? (Green Belt)
• ???????????????????
• ?????????????????
• ??????????????????????????????
• ????????????????????? ??????????????

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??????????????????

• ??????????????????? (Member)
• ???????????????????
• ???????????????????????????????
• ?????????????????????

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??????????????????

• ?????????????????????? (Process Owner)
• ??????????????????????
• ???????????????????????????????????????????

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??????????????????

• ???????????????? ?????????? (Master Black Belt)
• ????????????? ????????????????????????
• ??????????????????????????????????

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??????????????????

• ?????????????????? (Black Belt)
• ???????????
• ???????????????????????????????????????????????
• ????????????????????????????????????????
• ??????
• ????????????????????????????????????
• ????????????????????????????????????????
• ?????
• ???????????????????????????????? (Breakthrough)
• ?????????????????????????

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???????????????????? Critical Mass

• ??????????? (Member)

• ????????? (Green Belt)

• ?????????? (Black Belt)

• ???????? ?????????? (Master Black Belt)

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???????????? Six Sigma
????????????????? (Practical Problem)
?????????????????? (Statistical Problem)
?????????????????? (Practical Solution)
?????????????????? (Statistical Solution)
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???????????? Six Sigma

• ?????????????????

• ??????????????????????????????????????????????????
  ???? 85 ???????????????????????????????? 95
• ???????????????????????????????? ???????????????
• ??????????????????????????????????????

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???????????? Six Sigma

• ??????????????????

• ??????????????? (Input X) ????????????????????????
  ??????????????????? (Output Y) ???? X
  ???????????????????? ???? ??????? ???????????
  ???????????? ???????????????? ???????
• ??????????? ???????????????????? ??????? Y f(x)

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???????????? Six Sigma

• ????????????????

• ?????????????????????????????????????????????????
  (X) ??????????
• ???????????????????????????????????????? (Y)
  ????????????
• Y A BTemp CPress. ... Z ???????

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???????????? Six Sigma

• ??????????????????

• ?????????????????? (???? ???????? 125,
  ???????????????? ??? Pt, ???????)
  ??????????????????? ??????????????????????????????
  ??? ???????????????????????????

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???????????? Six Sigma

• Measure

• Analyze

????????????????? (Practical Problem)
?????????????????? (Statistical Problem)
?????????????????? (Practical Solution)
?????????????????? (Statistical Solution)

• Control

• Improve

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???????????????????? Phases of Breakthrough DMAIC
D
Define
M
Measure
A
Analyze
I
Improve
C
Control
Breakthrough !
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???????????????????? Phases of Breakthrough DMAIC
D
???????????????
M
????? Baseline
A
????? y f(x)
I
??????????????????? y f(x)
C
??????????????
Breakthrough !
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MAIC ??? ????????????????? Vital Few Concept
(Funnel)
30 - 50
Inputs Variables
MEASURE
Key Process Input
10 - 15
Variables ( KPIVs )
ANALYZE
8 - 10
KPIVs
4-8
Critical
KPIVs
IMPROVE
Key Leverage

3-6
CONTROL
KPIVs
Optimized Process
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??????????????? DMAIC

• Define/Measure
• ?????????????????????????
• ??????????????????????? ????????????
• ?????????? X ??? Y
• ?????????????????
• ?????????????????????? (Baseline Capability)

• Analyze
• ????????????? X ??? Y ????????????????? ????
  hypothesis, multi-vari, ANOVA ??? FMEA
• ??????? ????? ????????????????????????????????????
  ?????????? Noise
• ????????????????? DOE

• Control
• ???????????????????????????
• ??????????????????
• ??????????????????????
• ???????????????????????????

• Improve
• ????????????? X ??????????????????????? Y
  ???????????????????????????????? DOE
• ?????????? X ????????
• ??????????????????????????????????????????????

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Hidden Factory
Each defect must be detected, repaired and placed
back in the process. Each defect costs time and
money.
Manufacturing Variation Causes A "Hidden
Factory"Increased Cost - Lost Capacity