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Application of Six Sigma Methodology
to reduce Process Variation
Plenary Lecture @
The 3rd International Conference on
Basic Sciences, Faculty of Science,
Omar Al-Mukhtar University, Libya [
3rd October’2018
Presented By
Mr. Makkena Suresh
Asst. Professor , Faculty of Engg.
Omar Al-Mukhtar Univ, Libya10/4/2018
Objective
To present the Six Sigma Quality Improvement
methodology in simple and usable way
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Presentation Outline
1. Part 1
Overview of Six Sigma Quality
2. Part 2
Six Sigma Methodology - DMAIC
3. Part 3
Quality Costs & Benefits
Suitability of Six Sigma to Libya
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PART 1:
OVERVIEW OF SIX SIGMA
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What is ?
means Standard Deviation
Hence means Six Standard Deviations
Standard Deviation is the Variation (Deviation) from
the Mean (Average) value of a process
Six Sigma helps to reduce the variation in the
process.
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Variation in Heights of People
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Can we control this Variation ? No
Variation in Students Grades
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Can we control this Variation ? Yes
Management Reaction to Variation
J F M A M J J A S O N D J F M A M J J A S O
What
happened???!!! What
happened???!!!
Good Job!!
Good Job!!Good Job!!
Why do we need Six Sigma ?
To Improve Quality to World-Class Levels
What is Quality ?
Why should we improve the quality ?
Global Competition , Ex. Nokia , Kodak
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What is World-Class Quality Level ?
It is 99.99966 % Success Rate
In other words, it is 3.4 defects out of a million
opportunities. Six Sigma helps to reach this
level
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3 Sigma quality Level – 99.7 % Success Rate
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Why 6 Sigma ? Is 3 Sigma not enough ?
3 Sigma means, 99.7 % Quality Level.
According to a survey in the U.S.A , 99 % quality means:
22,000 wrong cheque transactions per hour
12 newborns will be given to the wrong parents each
day
Two unsafe planes landing at Chicago airport every
day
One hour of unsafe drinking water everyday
The list continues …..
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Defects at each Sigma Level
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PART 2:
Six Sigma Methodology - DMAIC
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Six Sigma Methodology - DMAIC
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Define Phase :What is the Problem ?
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Ex - Decrease defect rate to 1 %
Use Six Sigma Tools such as
Voice of Customer
Value stream Mapping
Process Map to find variables
Process thinking map
Fish Bone Diagram to list all
variables
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Measure Phase : Collect Data
Quantify the problem
Collect related data
Calculate Present Sigma level ,
process capability indices
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6σ
LSLUSL
widthprocess
ion widthspecificatCp
3σ
LSLμ,
3σ
μUSLminCpk
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Analyze Phase : Find the Root Cause
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Compare present Cp and Cpk with Six
Sigma standards (Cp or Cpk = 2)
Use - Fish Bone diagram to find root
causes
Identify the key variable . Establish
standards
Improve Phase : Reach Excellence
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Check the progress
Calculate new Cp and Cpk
Compare old and new capabilities
Improve the process
The goal is Cp , Cpk value of 2
Control Phase : Sustain the Gains
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Never allow workers to change
settings
Sustain Excellence – Check Progress
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PART 3: Quality Costs & Benefits
Six Sigma Suitability to Libya
Conclusions
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Quality Costs - Nasa challenger disaster (1986)
– 8 dead and over a Billion dollar loss
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The cause of accident was
A faulty O’ring Sealing, a kind of
Washer used to prevent escape of
Hot gasses from the engine.
It failed to expand under cold
weather.
http://www.spacesafetymagazine.com/space-disasters/challenger-disaster/challenger-management-failure/
Quality Costs - Toyota takes $2bn hit from
global safety recall (2010)
Carmaker Toyota had
brake problems with
Prius
Toyota suffered $2bn
(£1.26bn) extra costs
as a result of a global
safety recall
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Source:
https://www.theguardian.com/business/2010/feb/04/toyota-safety-recall-profits
Benefits of Six Sigma
U.S. Army
Using Six Sigma methods, saved over $2 billion.
General Electric
Reduced costs in excess of $1.8 billion.
Allied Signal
Saved $800 million by implementing Six Sigma
Lift Truck Manufacturer
Saves $1.5 Million Since Adopting Six Sigma
Source: http://www.sixsigmadaily.com/saving-start-lean-six-sigma/
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Is Six Sigma Suitable to Libya ?
Yes, It is certainly suitable
My own research conducted at Animal Feed plant
located in Shahaat indicated that, Libyan Industries
are suitable for the implementation of Six sigma.
Click Here to access the Research Paper
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Conclusions:
Six Sigma Quality Improvement process can
be applied to any Organization.
It is possible to implement Six Sigma in
Libya , as there is a huge scope for
improvement here.
Six Sigma helps organizations to reach
World-Class Quality Levels.
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References
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Backup slides
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W
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How to start Six Sigma journey ?
Immediately , after
getting short training
There are various levels
of Six Sigma
certification - Yellow,
Green, Black and Red
Belts
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Who offers Six Sigma Certification ?
American Society for Quality
Institute of Industrial Engineers
Chartered Quality Institut
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How much does it Cost for Six
Sigma certification ? The cost for the IASSC Certified Black Belt
Exam is $395 USD.
The cost for the IASSC Certified Green Belt
Exam is $295 USD.
The cost for the IASSC Certified Yellow Belt
Exam is $195 USD.
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How long will it take to see the benefits
of Six Sigma ?
3 months to 5 years depending upon the
scale of the project.
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Universities offering 6 Sigma certificate
programs
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University certification programs[edit]
Arizona State University[1]
Binghamton University, State University of New York[2]
Brigham Young University[3]
Brigham Young University - Hawaii[4]
Boston University[5]
California State University, Fullerton[6]
Case Western Reserve University[7]
Cleveland State University[8]
Cornell University [9]
Dartmouth College[10]
Emory University[11]
Franklin University[12]
George Washington University[13]
Georgia Institute of Technology[14]
Louisiana Tech University[22]
North Carolina State University[
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