6s(Six Sigma)???

1
6s(Six Sigma)???
6s
2
??
?. ???6s? ?. ??????6s? ?. ????6s? . 6s
?????
2/44
3
?. ???6s?
1. ?????? 2. 6s??????? 3. 6s??? 4. 6s??? 5.
6s????? 6. 6s???Process 7. ????? Tool??? 8.
6s???
3/44
4
1. ??????
?. ???6s?
? ?????
Sample 10???? (?? 1004)
?? (N1,000)
?? ??
?? ??

• ?????????
• ????????!

?
?
?
?
?
?? (Sample,n)
?
?
?
?
?
102
96
97
98
99
100
104
101
103

• ??Sample?????
• (??????)?
• ????

? 10?Sample???????,????????,
????????????,???????2.8??? ?? Epidemic
????? ? ????????,??? Process???????,
????Process?????
4/44
5
?. ???6s?
2. 6s???????
???? (?????? T)
????Target??
????? Target
T
T
USL
USL
6s ??? ?? ??? ?? ??
USL
USL
µ
µ
???,??????
T
USL
USL
µ
???? (????)
5/44
6
?. ???6s?
3. 6s???
??????6s
???
????
????
6.68
3 s
s
- 3 s

• s????????,
• ??(s)?,????
• ???????6?s
• ????? 6s.
• ??,????????
• ??3.4ppm,??,???
• ????????Process
• ???.

3.4ppm
6 s
s
6 s
- 6 s
????(Standard Deviation,s) ???
Data??????????????
6/44
7
?. ???6s?
3. 6s???
???????
s PPM

• ????????????????
• 1?????????340?????
• 1?????1.8????

6 3.4 5 233 4 6,210 3
66,807 2 308,537

• ??????1.5??????
• 1?????????670??????
• 1?????24?

7/44
8
?. ???6s?
3. 6s???
6s?????
6s????

• ????????
• ????????
• ?????????,
• ???????,
• ???????????,???????
• ?????????????.

3.4 PPM ?? (???? 3.4???) Cp2.0, Cpk1.5
?) PPM Parts per Million, ?????????? Cp
Process Capability Index,?????? Cpk
?????????????????
8/44
9
4. 6s???
?. ???6s?
1. ????????

• ???????????,?????????
• sigma??????????????????

2. ??Tool???
????,??,??,???? Biz. System???? Full
Package??Tool?
3. ????

• ????????????????
• ??Process??????????Target??????????????/??

4. ????

• ???????????????,??loss?
• ????????????

9/44
10
4. 6s???
?. ???6s?
??s - Level???
6s???

• ????????????

5s?? - ?????

• ??????
• ????????

4s?? - ?????

• ?????????
• QC 7tool???

3s?? - ??????

• ????????
• ???????

10/44
11
5. 6s?????
?. ???6s?
6s???,??,????? Business System?? Application?
Tool.
????????????
??

• ?????????,??CTQ
• ????? Tolerance
• ???????CTQ?????

RD 6s
??
6s
?????????
??
??

• ??S/W??Field????
• ??I.T Real Time Monitoring
• ? ??????

??
Manufacturing 6s
Transaction 6s
??
????? Output?????

• ?????????
• ?????Focusing??

11/44
12
?. ???6s?
6. 6s??Process
6s?? Process(Manufacturing Transaction)
?????? CTQ???? (Critical to Quality)
1. ???????? - ?? - ?? 2. ??????????? 3.
???????,???????
D
?? CTQ????? ?? Process
1. ?????????SVC? CTQ ?? Process???? 2. ?
Process?????????
????????

• Practical Problem
• Measurement System
• Yield Calculation

• Process Mapping
• s Calculation

easure
M
M
nalyze
A
mprove
I

• Benchmarking
• Pareto Chart Stratification

• Cause Effect Diagram

A
ontrol
C

• ????
• Brainstorming

• Action Workout Techniques
• Piloting

I
6 Sigma???????,?? ???? Process? Package!!!

• Control Mechanism
• ???

• Procedures

C
CTQ(Critical To Quality) ??????????,
Service?? Process???? D Define
12/44
13
?. ???6s?
6. 6s??Process
?? RD 6s?? Process
?? ?? ???
?? ?? ???
E/S ?? ??
?? ?? ???
Kick -Off
?? Process
?? Needs ??
QFD S-1
?? CTQ ??
?? ?? Data ??
CTQ? Z? ??
CTQ ?? ??
Z? ???, ?? ??
QFD S-2
?? FMEA
?? FMEA
RD 6s
E/S ??
???? ??
?? ??
E/S ???
P/L ??
P/L ???
?? ??
P.P ??
P.P ???
CTQ ?? Data ??
?? ?? ??
CTQ ?? ??
CTQ ??
CTQ? Z? ??
13/44
14
?. ???6s?
7. ????? Tool???
?? Process ??
????
? ?
? ?
? ?
- ???? ????
- ???? ?Idea ????
- ????? ???? - Process 4M??
- ???? - ????
- ???????????? - ?????Tool??, ????????
??

• ??/??
• ??

6s
- ???????????? - ???? Process?? ??????? S/W
??????(Package?)
- Define/?? ?? - CTQ??? ??
- ????? ?? - ????? ??????
- ???? ??? ????
- ??PTS? ???? (CTQ, ??)
Project Tracking System Project ????? System
14/44
15
?. ???6s?
7. ????? Tool???
100ppm ? 6s ??
100ppm / 6s ??
100ppm
6s
? ?? Line ?? ? ?? FMEA ?? -
??????? Cost Impact???? ? CTQ
????? ? ?????? - ?????? -
?????? - ?????? - ?????? ?
? ?????? 100ppm / 6s ??

• ???????

• ???????

• ?? Tool

• ?? Tool

• ?????????

• ???????
• ??????

• ?????Know-How
• ????

• ????Data
• ????

• ???? Data?
• ???????

• ????S/W
• ?????
• ??

15/44
16
8. 6s???
?. ???6s?
Focusing Point
CTQ(Y)F(X1,X2,X3, ... Xn )
6s?????System?,???? ??Cost Impact????,??CTQ
????CTQ? 6s???????? 6s???????? CTQ ??????,
???????????? (X1, X2..) Focusing ????
?
Y
X
? ???? ? Input ? ?? ? ??? ? ????
? ???? ? Output ? ?? ? ?? ? ??,?????
?
?? CTQ(Y)? X????20??? ?????80????????? ??
16/44
17
8. 6s???
?. ???6s?
? ???????????? ? ???????????????? ?
???????????? ? ??????????????
17/44
18
8. 6s???
?. ???6s?
? ????????????. ? ????????????. ?
?????????????QCD. ? ??????QCD????????. ?
???????????????. ? ???????????????????. ?
????????????????????. ? ?????????????????. ?
??????????????.
QCD (Quality, Cost, Delivery) ??,??,??
18/44
19
?. ??????6s?
1. ??????? 2. Paradigm Shift 3. 6s???
4. ????
19/44
20
?. ??????6s?
1. ???????
??????
SVC ??? ()
?
???? ??????
?
?
?
?
?
96
97
98
2002
93
???? ???? SVC ?????
20/44
21
?. ??????6s?
1. ???????
???????????????
??
????????? ( ????)
??
SVC
Retouch
Reject
????
????
????????? (????)
Long cycle time
????
?????
???????
????
????
21/44
22
?. ??????6s?
2. Paradigm Shift
????? Paradigm Shift
??????
??????
?? ?? ??
?? ?? ??
? ?
? ?
? ?
? ?
?? ??
?? ??
???? ?????
???? ?????
4s
5s
4s
6s
??
??
???????????????,??????????
22/44
23
?. ??????6s?
2. Paradigm Shift
3s / 6s ????
3 s ?????
6 s?????

• ???? 5???Cost
• ??????? 3-4????
• ??????? Process
• ??????????
• ??????????????????
• ????????? Benchmarking
• ???99???
• ????CTQ (???????? CTQ)

• ???? 10-25???Cost
• ??????? 66,807????
• ?????????
• ??????????
• ??Data????????????
• ??????? Benchmarking
• 99???????????
• ????CTQ

23/44
24
?. ??????6s?
2. Paradigm Shift
99 ??????????

• ???????????.
• ???15????????.
• ????5000??????.
• ???????????????.
• ???20???????.
• ???7????.

4 s 99.38
24/44
25
?. ??????6s?
3. 6s???
???????? 6s???????
???????
6s????
ISSUE

• (???)
• ??? Data
• ??????
• Spec????(????)
• ?? ??
• Bottom Up
• ????

• sigma (s)
• ??? ??? Data
• ????
• Spec?(????)
• ?? ???? ????
• Top Down
• ??, ??, ??????

???? Data ?? ???? ???? ???? ????
25/44
26
?. ??????6s?
3. 6s???
6s???

• ?????????
• ??????????
• ???????????
• ??S/W??
• ?????Data??
• ??Data

? ?????????? ? ???????? ? ????????? ?
?????????? ? ?????????? ? ?????????
26/44
27
?. ??????6s?
3. 6s???
6s ???? / ???
???? ????????, ?????????? , ???????
?????????
???
??????? ??????????????
3P Focus ???????? ????????,????????proces
s,???????????, ?????????,??????
????? ?Hardware?????,?????????????
?????????? ?Project????,??(??,??)??????,??
????, ???????????
Data Driven Mind?????,QC Tool????.
??????? Data,?? Data, ?????????,
?????????.?? S/W??????.
3P Product, Process, People(??, ??, ??)
27/44
28
?. ??????6s?
4. ????
6s ?????
?? G.E
?? Motorola

• 80????,????????,????
• ????????????
• 81??? 5?? 10?????????,
• ??????,????????GAP??
• ??????????????????,
• ??????????,??????,
• ??? 6s?
• 87????????? Key Initiative
• ??6s??

• 95???????????,????
• ????,?? World Class Quality,
• Launching???
• ???Productivity,Inventory Return,
• NPI???,???????Process
• process ?????????
• GE?? World Class Quality????
• ??,GE ???????????
• Focusing 6s.

28/44
29
?. ??????6s?
4. ????
???????
MOTOROLA T I G E
SONY
?? ?? ?? ?? ??
1987? 1988? 1995?
1997? ?????? ????
???????? ?2000?2000? 32?
198830 38? (2000?) Black Belt??
?19937.4 6s???
?????Team ????/?? ??????? (4??????100?)
?? ????? ???????? TOP
DOWN ???project ? 6s???
???? ???? ????
29/44
30
?. ??????6s?
4. ????
??????
????
????
Motorola ??
Motorola??92???5.5s??, 87??92????32??????
1200
Costs

• 6s?????? Boundaryless
• Behavior ????.
• ?????,????????
• ?? 6s ??????????
• GE?? 6s ?????? Central
• Role

1000
Benefits
800
G E ??
600
400
200
0
96
97
98
30/44
31
?. ????6s?
1. 6s ????? 2. 6s ????? 3. Project ?? 4.
Infra ????
31/44
32
?. ????6s?
1. 6s ?????
System???
Method???
Top Down???
???????

• ????????????
• Top management????
• ?????6s???

• ????????? CTQ,
• Impact???????

???????????
????????? Program

• ?????????,???
• ????????????
• Process Redesign(????)

• ????,?? Tool? Process,
• ??????.
• ???????????

? 6s??????????
??????(Infra)

• ??????????(CTQ,s,Cp,...)
• ????,???? s??
• ? Project???????

• ????? Project,?? Infra
• ???,???,?????
• ??????????? System

32/44
33
?. ????6s?
2. 6s ?????
?????
- 6s ???? - 6s Involvement Commitment
Champion
- 6s ????
Support
????/ ????
Commitment
Commitment
Champion Review
??/??
Project Team
MBB(Master Black Belt)
????
- ????? Project ?? - ?CTQ ??6s??
- 6s Skill ??
Champion Review ????Champion??(Theme?? ?
????) ??????????????.
33/44
34
?. ????6s?
2. 6s ?????
Champion
? ?
? ?
- Vision???

• ?????6s??
• ????????????????
• ?Project?????????

- 6s ?? Drive

• ????6s???
• ????(OBU?, ????,
• ????)?? Champion?
• ??

• ???? Commitment??????
• ?MBB??????????

- Involvement

• ??Champion Review,?? Monitoring???
• ????,??6s?????

- Project ??

• ??/???????????????
• ????? Resource??
• ???????????? F-Up ? Monitoring
• ???????? Ownership?

?6s?? Ownership ? Project ?? Involvement??????
34/44
35
?. ????6s?
2. 6s ?????
M B B(Master Black Belt)
? ?
? ?
- Skill??

• ????????6s????
• ??6sSkill Tools? Level up
• ??????

• 6sTechnical Leader
• Full Time Job ??6s
• MBB????????????
• ???????????

- 6s ?? Drive

• ??? Check Project ????
• ??? Champion Feedback Project ????????
• ????????

- Project??/??

• 6s??? BB/GB ??
• ????,??6s?????
• ??????????? Process

?????? MBB ???? Skill up ??????
35/44
36
?. ????6s?
2. 6s ?????
Belt ??
? ?
? ?
Role
? ?

• BB / GB ??
• Project?? Drive
• ????????
• ??

• 6s Technical Leader
• ?????Background
• ?? Skill

• ?? 6s????
• .MBB?? Course???
• . 6s Project??????
• ?????,??
• ???? ??5????? Project

Master Blackbelt

• ? Neck?????
• Full Time Project

• ?? Project
• ??Team Leader
• Team? Tool??

• Task Project ?? Leader
• .?? 6s Project 2?????
• .?? ???????? Project

Blackbelt

• ? Neck?????
• Part Time Project

• ?? Project
• ??Team Leader

• Project??? Task Member
• ?? 6s Project ??????

Greenbelt

• ????

• ?? Project??
• ?? 6s???????????

• ?? Project
• ??Team??

Whitebelt
36/44
37
?. ????6s?
3. Project ??
PTS ?? Flow
????
- ???? Project CTQ ???? ???? -
Project????????? - 6sProject? Cost????? - Project
??????? - 6sProject ??????
All Projects
Project Reviews
PTS
Belt
Champion, ?????
- Defect Data,?? - ?????? - ???? - ????? (??
Update)

• ?? Review
• Cost, ??,????
• ??, ??
• ???? Check

• Project??/CTQ? Z???/????
• ????/OBU/??/MODEL???

Home Appliance ??????? 6s System ?, ??99??????.
PTS Project Tracking System
37/44
38
?. ????6s?
4. Infra ????
??????????
6s?? ????
6s?? ????
????? ??
6s?? ????
?? Project ??
- 6s ???? - 6s ???? / ????
- ??????? Minitab S/W - ????? IT
Real Time Monitoring CTQ Data
Gathering - ??????? IT System - PTS
Project Tracking System
- 6s?? ?????? - 6s???? ??????
- 6s ???? ????/?? - ??? 6s??
???/???
- ???? MFG QA?? RD ???? -
6s?????? 23? / OBU ? ?? 6sTeam
??(57?)
- ??????? - ?????? ? Project Review
- Coreman 80?/? - ????? 2,400?
- 6s Team - ?? Project ??1?/OBU
Home Appliance ??????
38/44
39
. 6s????
1. CTQ 2. DPU / DPMO 3. Z ? 4. ?????? 5. ?????
39/44
40
1. CTQ
. 6s????
CTQ???
?? CTQ Tool
Critical To Quality?????????, ????????????,Servic
e??? ? Process????
?

• ????
• Focus Groups Interview
• ???????? Mapping
• ??????(QFD)
• Quick Market Intelligence
• Logic Tree
• Pareto Diagram

????????????????? CTQ
?
?)

• ????? Spec.
• ?????????????(???)
• ????????
• ??

?
??????????????? ???,?6s????,??? ?? CTQ??????.
????????,???????.
40/44
41
. 6s????
2. DPU / DPMO
Defects Per Unit ?? Unit???? Defect?? ? ??
Process??????,?6s????????? ????????.??????
?) ????? Claim????10???????,??
????2????? DPU Defect / Unit
????/?????? 2 / 1 2
DPU
Defects Per Opportunity ??Unit??????????
Unit???? Defect? ? ??????????????????????????
Process??????, ? DPU??????????. ?)
????(Unit) Claim???????????10?,???????2?
2 Defect / (1Unit x 10 Opportunity) 0.2 ??,
DPO0.2
DPO
Defect Per Million Opportunities DPO? x
1,000,000, ? 6s?????? PPM(Part Per
Million).??,Scale?????????. ?) DPMO 0.2 DPO
x 1,000,000 200,000
DPMO
41/44
42
3. Z ?
. 6s????
Z????
Z????
????????,???????? ???????????,
?
???? X (???? USL ??LSL) ????????,?????(s)?? ??
?????? Z?.
?
? ???? Process?????????, ????(s)??,????6????
?,?? Z6??6s??? Process? ?. ??
3.4ppm,????????? 34???????? Process??.
?? sLevel??????, Z6?? 6s??.
?
???? ???(µ)??????????????????????
?????? ???? 0,????? 1?????
USL (Upper Spec Limit) ???? / LSL (Lower
Spec Limit) ????
42/44
43
4. ??????
. 6s????
? ???????(Process Capability)?
??????????????????????????
??????
m
T
- ?????????????? ?????????? -
??????Z????????? ???????, ??? Cp,
Cpk - ?????? Cpk??????? ??,???????. -
?????(T)????????? ?????????K????.
3s
-3s
6s
-6s
1s
?????
????
??????????(????)
Cp
??????(?????)
T-µ
Cpk Cp (1-K)
K
(???? - ????)/2
43/44
44
5. ?????
. 6s????
? ????????????????????.
Input
??
??????,?????
??1 99 ???
?? ??? ??
??????,????,??? Model Change Loss,????
??
??2 92
Tool
6s
??3 93
?? ??? ??
???? 97
??1?Project,????, ??Team????
??
?? ??
?? ???
???? Loss
?????????? ?????????
RTY 0.99 X 0.92 X 0.97 X 0.97 85.7
RTY(Rolled Throughput Yield) ?????
44/44