Six-Sigma Quality

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Six-Sigma Quality

• The second pillar of the Toyota Production
  System is Jidoka
• A system for detecting defects and abnormal
  conditions in production
• Automatically stopping a line so that quality
  issues can be quickly addressed.

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House of Toyota
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Data Driven Approach

• In even the leanest manufacturing plants, some
  quality issues arise that are difficult to
  identify and correct
• Six Sigma is especially effective at identifying
  the root cause of quality problems and
  eliminating defects by reducing variation in
  manufacturing processes

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Variation - The Root Of All Process Evil

• As a customer, the worst experience I can imagine
  is being a casualty of process variation. 'It
  doesn't seem that bad,' you may be thinking to
  yourself. Just remember back to the last time
  you

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Remember When You

• Went grocery shopping only to select the slowest
  teller in the store
• Received a haircut that was shorter or longer
  than usual, and definitely not what you asked for
  
• Decided to go shoe shopping, but got stuck with
  the most ignorant salesperson available

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• Consider the general concept of variation by
  examining the preparation time (in minutes) of 10
  pizzas being prepared by your two local pie
  shops. The times are listed below
• ABC Pizzeria
• XYZ Pizza To Go

6.5 6.6 6.7 6.8 7.1 7.3 7.4 7.7 7.7 7.7
4.2 5.4 5.8 6.2 6.7 7.7 7.7 8.5 9.3 10
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• If we use common statistical tools, such as Mean,
  Mode and Midrange, we get the following results

ABC Pizzeria XYZ Pizza To Go
Mean 7.15 7.15
Mode 7.7 7.7
Midrange 7.1 7.1
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• From these results the two pizza parlors have the
  same measures of central tendency, so, on
  average, customers wait the same amount of time
  for pizzas at the two restaurants
• Based on these measurements alone, we cannot see
  any distinguishable difference between the two
  processes

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• Return to the original data points, There is a
  very distinguishable difference ABC Pizza has
  preparation times with much less variation than
  the times for XYZ Pizza.
• ABC Pizzeria
• XYZ Pizza To Go

6.5 6.6 6.7 6.8 7.1 7.3 7.4 7.7 7.7 7.7
4.2 5.4 5.8 6.2 6.7 7.7 7.7 8.5 9.3 10
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• If all other characteristics of the pizza (taste,
  temperature, size, topping quality, service
  friendliness, etc.) are equal, customers are
  likely to prefer the ABC Pizza where they will
  not become annoyed by being the one person whose
  pizza preparation time is much slower than the
  others

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• Six Sigma at many organizations simply means a
  measure of quality that strives for near
  perfection
• Six Sigma is a disciplined, data-driven approach
  and methodology for eliminating defects
• Driving towards six standard deviations between
  the mean and the nearest specification limit in
  any process -- from manufacturing to
  transactional and from product to service

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• From a manufacturing standpoint, that means just
  3.4 defects per million products or parts made
• Surprisingly, manufacturing 99 without defects
  means youll have 10,000 defects per million
  and at 95 that number jumps to 50,000 defects.

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• The quality tools and techniques that were named
  Six Sigma in 1986 by Motorola (actually by a
  Motorola engineer named Bill Smith) are not new
• They were developed over the past 50 or more
  years, through the work of quality experts such
  as Deming, Juran and others.

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The Journey
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Data Driven Approach

• Despite the use of the term today, Six Sigma is
  actually a numerical measurement of quality
• To achieve Six Sigma, precisely 99.99966 of what
  you do must be without defects

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Key Concepts of Six Sigma

• Critical to Quality
• Defect
• Process Capability

• Attributes most important to the customer
• Failing to deliver what the customer wants
• What your process can deliver

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Key Concepts of Six Sigma

• What the customer sees and feels
• Ensuring consistent, predictable processes to
  improve what the customer sees and feels
• Designing to meet customer needs and process
  capability

• Variation
• Stable Operations
• Design for Six Sigma

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Deming Juran
It is not necessary to change. Survival is not
mandatory.
W. Edwards Deming
"Without a standard there is no logical basis for
making a decision or taking action." Joseph M.
Juran