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6 . Six Sigma Quality. Presented by: ENRICO C. MINA. Objectives. At the end of this course, the participants will have: Learned the basic principles and concepts Appreciated the Six Sigma Road Map and its possible applicability to their own organization - PowerPoint PPT Presentation
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1
6Six Sigma Quality
Presented by:
ENRICO C. MINA
2
Objectives
• At the end of this course, the participants will have:– Learned the basic principles and concepts– Appreciated the Six Sigma Road Map and its
possible applicability to their own organization– Learned and applied the fundamentals of 6σ
Measures and Scoring System
3
Six Sigma Quality Philosophy
Six Sigma (6) is a specification-based philosophy. It sets a
defects target.
4
Six Sigma Definitions• Highly technical method used by engineers and
statisticians to fine-tune products and processes
• A goal of near-perfection in meeting customer requirements (3.4 defects per million opportunities)
• A sweeping “culture change” effort to position a company for greater customer satisfaction, profitability and competitiveness
5
6 Target• Customer Satisfaction
• Product Quality Perfection
• 4 defects per million
• 12- Span• Maximum Probability of Making a Good
Product/Service
• Zero Probability of Non-Conformance
• A process design second to none
6
Review
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The 3 Control (1)
0.135%
-3 -2 -1 0 1 2 3
0.135%
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Traditional SPC
The 3- Control Chart
CL
UCL
LCL
Mean
1st line
1st line
2nd line
2nd line
3rd line
3rd line
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The 3 Control Chart
• Known as 6 Process Capability
• System Performance
• Voice of the Process
• Independent of the Customer Specifications
• Used to hunt out of control situations
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Process Capability (6)
-3 -2 -1 0 1 2 3
6
UCLLCL
CL
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The 3 Control
Even if the process is in the state of statistical control, there is still a
chance that 2700 parts per million (ppm) observations or 0.27 lie outside of its sphere of control.
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CONTROL LIMITS & TOLERANCE LIMITS
• Control Limits – process or system normal limits of performance. Established as a function of averages.
• Tolerance Limits – are customer specification limits referring to the highest & lowest individual values that can be considered acceptable.
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Process Capability (6) & Tolerance
Case I: 6 < U - L - Most desirable caseCase II: 6 = U - L - This is good as long as the process is in a state of controlCase III: 6 > U - L - Undesirable situation
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Case III: 6 > U - L - Undesirable situation
6 Process Capability
Tolerance UTLLTL
UCLLCL
Target Value
RejectReject
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Case II: 6 = U - L - Good as long as the process is in a state of control
6 Process Capability
Tolerance
Rejects are due to random variations only = 0.135%
UTLLTL
UCLLCL
Target Value
0.135%
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Case I: 6 < U - L - Most desirable case
6 Process Capability
Tolerance
Rejects are still possible but the probability is very low
UTLLTL
UCLLCL
Target Value
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The 3 Control
0.135%
-3 -2 -1 0 1 2 3
0.135%
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The 3 Control (3)Ex: With 3-, a product that contains 1000 parts
• can expect an average of 2.7 defects per product unit
• has probability of 0.99731000 or 6.7% that a product contains no defective parts
• can expect 7 units per hundred will go without defects!
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The 3 Control (4)
•The 3- quality is not sufficient!
• Product or process must be designed to tolerance limits that are significantly more than + 3 from the mean.
20
Cost of Quality
• Costs of rework
• Cost of scrapped materials/products
• Cost of inefficiency
• Cost of delay
• Cost of excess manpower
• Cost of excess overhead
• Cost due to unhappy or lost customers
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Six Sigma Definition A comprehensive and flexible system for
achieving, sustaining and maximizing
business success. It is driven by : • close understanding of customer needs• disciplined use of facts• data and statistical analysis• diligent attention to managing, improving and
reinventing business processes
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6 Control
• Used to prevent losses attributable to common-cause variation
• Used to find out whether your attempts to reduce common-cause variation are working
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Benefits of Six Sigma• Cost Reduction
• Productivity Improvement
• Market-share growth
• Higher Profitability
• Customer retention
• Cycle-time reduction
• Defect reduction
• Culture change
• Product/service development
"Customer satisfaction, top-line results, operating margins and cash flow are all improved by Six Sigma." - James W. Rogers, President and CEO, GE Industrial Control Systems
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Motorola
• Early 80s - Top leaders conceded that the quality of its products was awful
• 1987 - Six Sigma concept was introduced
• 1988 - honored with the Malcolm Baldrige National Quality Award
• 1988-97 - Five-fold growth in sales, $14 billion savings due to 6 sigma, stock price of 21.3% increase annually
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Process capability index (Cp) and product outside specification limits
Process capability index (Cp)
Total product outside two-sided specification limits*
0.5
0.67
1.00
1.33
1.63
2.00
13.36%
4.55%
0.3%
64 ppm
1 ppm
0*Assuming the process is centered midway between the specification limits.
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Customer Expectations have changed
"In the past, customers were happy if 99.5 percent of the parts you gave them worked
with no problem. Now world-class companies want only 200 rejects for every
million parts and, ultimately, they want zero." - John Bertrand, President, A.O. Smith
Electrical Products Company
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Du Pont
"Six Sigma implementation continues to gain momentum. At the end of the year
2000, there were about 1,100 trained Black Belts and over 3,400 active projects. The
potential pretax benefit from active projects was $700 million." - DuPont Fourth Quarter
and Full Year 2000 Earnings Report
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General Electric
"The Six Sigma initiative is in its fifth year — its fifth trip through the operating
system. From a standing start in 1996, with no financial benefit to the Company,
it has flourished to the point where it produced more than $2 billion in benefits
in 1999, with much more to come this decade." - GE 1999 Annual Report
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Honeywell
"We achieved $600 million in Six Sigma cost savings in 1999, but cost savings are only one part of the story.
Delighting customers and accelerating growth completes the picture. When we are more efficient and
improve work flow throughout every function in the company, we provide tremendous added value to our customers – through higher quality solutions that are
more competitively priced, delivered on time and invoiced correctly. That makes us a more desirable business partner." - Honeywell 1999 Annual Report
30
Toshiba Corp.
"Toshiba Corp. expects to cut operational costs by Y130 Billion in the current fiscal
year ending March 2001 by using Six Sigma, a company spokesman confirmed."
- Wall Street Journal November 5, 2000
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Six Sigma Principles
1. Customer focus 2. Data driven control3. Process improvement4. Proactive management5. Boundaryless teamwork 6. Continuous quest for
perfection
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The Business Process Model 1
InputsProducts $
Y
YY
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Workshop # 1 - First Production Run
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The Business Process Model 2
InputsProducts $
XXXX
X
Y
YY
Y = f(x)
35
CTQ
• “Critical to quality” characteristics
• Key results
• “Ys” of the process
• Upstream variable
• Dependent variable
36
Yield
Percentage of products or items without defects
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Defect
Any instance or event in which the product or process fails to meet a customer requirement or anything outside of
customer specifications.
It goes without saying therefore, that in order to recognize a defect, the point of success must have been specified as a prior customer requirement.
38
Six Sigma Opportunity
The total quantity of chances for a defect.
In other words, a six sigma opportunity are all the things that can go wrong in a product or service that can cause dissatisfaction to the customer.
39
DPMO
• Defects per million opportunities
• The number of errors that would show up if an activity is repeated a million times.
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Six Sigma ScoreSimplified Sigma Conversion Table:
% Yield DPMO Sigma Score
30.9 690,000 1.0
69.2 308,000 2.0
93.3 66,800 3.0
99.4 6,210 4.0
99.98 230 5.0
99.9997 3.4 6.0
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Six Sigma Measure
• Clearly define what customer requirements are
• Provide a consistent metric
• Link to an ambitious goal of 99.99966% yield.
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Six Sigma Strategies
ProcessImprovement
Process Design/Redesign
Process Management
S C S C
S C
43
Process Improvement
• Find problems
• Analyze problems
• Find root causes
• Develop focused solutions
• Implement and evaluate solutions
• Continuously improve the process
44
Process Design/Redesign• What is the value that the customer wants?
• What is the current way of delivering this value?
• What is the best, fastest, simplest, safest and cheapest way of doing it? Is there anyone who has successfully done it? How?
• What is the gap between the current way and the ideal way?
• What must change to eliminate the gap?
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Process Management (1)
• Processes are documented & managed end-to-end
• Responsibilities have been assigned to ensure success
• Customer requirements are clearly defined & regularly updated
• Measures of outputs, process activities & inputs are thorough & meaningful
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Process Management (2)
• Managers & process owners use the measures to assess performance in real time
• Actions are taken to address problems & opportunities
• Six Sigma tools are used to raise the company performance
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The DMAIC Model
?
1. Define2. Measure
3. Analyze
4. Improve
5. Control
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DefineProcess Improvement Identify the problem
Define requirements Set Goal
Process Design/Redesign Identify specific or broad
problems Define goal/change vision Clarify scope & customer
requirements
??1
49
Measure
Process Improvement Validate problem/process
Redefine problem/goal Measure key steps/inputs
Process Design/Redesign Measure performance to
requirements Gather process efficiency data
2
50
Analyze
Process Improvement Develop causal
hypothesis Identify “vital few” root
causes Validate hypothesis
Process Design/Redesign Identify “best practices” Assess process design
- value/non-value adding- bottlenecks/disconnects- alternate paths
Refine requirements
3
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Improve4Process Improvement Develop ideas to remove
root causes Test solutions Standardize solution/
measure results
Process Design/Redesign Design new process
- challenge assumptions- apply creativity- workflow principles
Implement new process, structures, systems
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Control5Process Improvement Establish standard
measures to maintain performance
Correct problems as needed
Process Design/Redesign Establish measures & reviews
to maintain performance
Correct problems as needed
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The Six Sigma DMADV process
Define, Measure, Analyze, Design, Verify is an improvement system used to develop new processes or products at Six Sigma quality levels
M
D
AD
V
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The Six Sigma Road Map
$$$1. Identify core processes & key customers
2. Define customers requirements
3. Measure current performance
4. Prioritize, analyze & implement improvements
5. Expand & integrate the 6 System
DM
AIC
MD
ADV
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1. Identify core processes & key customers
• Identify “Core” business processes• Define process Outputs & key Customers• Create high-level Core process maps
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Core Process
• Core Processes are value creating activities for which your customers pay you
• Resources & efforts used in the core process find their way to the customer
• It is an end-to-end chain of processes that delivers a product or service
• The Core Processes are supported by Support Processes
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The SIPOC Process Model SIPOC stands for:• Supplier - the person or group providing key
information, materials or other resource to the process• Input - the “thing” provided• Process - the set of steps that transforms or adds
value to the input• Output - the final product of the process• Customer - the person, group or process that
receives the Output
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2. Define customers requirements
• Gather customer data: develop “Voice of the Customer” strategy
• Develop performance standards & requirements statements
• Analyze & prioritize requirements; evaluate per business strategy
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Gather customer data: develop voice of the customer “strategy”
• Get information from the following:– Current, happy customers
– Current, unhappy customers ( that include both those who complain and those who don’t)
– Lost customers
– Competitors’ customers
– Prospective customers - those who haven’t purchased from you or your competitors, but are potential buyers of your products/services
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Develop Performance Standards & Requirements Statements
• Output Requirements - are the features & or characteristics of the final product or service that are delivered to the customer at the end of the process.
• Service Requirements - are guidelines for how the customer should be treated/served during the execution of the process & delivery of the output
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Examples of Output & Service Requirements Manufacturing
• Must maintain a max. of 10 units (1 tray) buffer all the time
• 60 secs. response time for an order
• Must use the orange tray
• Units are placed in slots according to production sequence
Service Requirements Output Requirements
Process Typical Rqmts. Output Typical Rqmts.
Assembly of Module A
Module • The circuit is closed
• Every solder point appears excellent
• No scratches on the surface
• Impedance test is 90-100 ohms
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Requirement Statement
A brief but thorough description of the performance standard established for an
output or service encounter
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Examples of Requirement Statements
Poorly Written Well-Written
The module is in excellent condition & properly functioning
• No scratches on the surface
• Cord length is 2 meters
• Pilot lamp lights up when switched on
• Power outlets are correctly labeled
• Power indicator reads 220 volts plus or minus 10 volts
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Analyzing & Prioritizing Customer Requirements; Linking
Requirements to Strategy
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Three categories of Customer Requirements According to Dr. Noriaki Kano
• Dissatisfiers or Basic Requirements. These are factors, features or performance standards that customer absolutely expect to be met.
• Satisfiers Variable Requirements. These are factors that makes our rating from the customer higher or lower. (Ex: price. courteous treatment, etc.).
• Delighters or Latent Requirements. These are product or service features that go beyond what customer expect. (Ex: welcome drink in a hotel, key light in cars etc.).
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Workshop # 2 - Customer Grill
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3. Measure current performance
• Plan and execute measures of performance against customer requirements
• Develop baseline defect measures & identify improvement opportunities
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Continuous vs. Discrete Measure
• Continuous measures are those factors that can be measured on an infinitely divisible scale or continuum; e.g., weight, height, time, decibels, temperature, ohms, money.
• Discrete measures are countable dataa.) Characteristics or attributes - such as level of education (high
school, Bachelors degree, etc.); or type (for example, an airliner might be Boeing 737 or 747, or Airbus 300)
b.) Counts of individual items (e.g. number of credit cards, wafers, numbers of orders processed).
c.) Artificial scales, like rating a record from 1 to 5 (good beat, easy to dance to) or describing your level of satisfaction with service.
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Discrete & Continuous Measure Examples
Discrete Continuous Discrete• Number of typographical
errors
• Rating of service
• Units delivered per day
• Number of claims in dispute
• Number of shafts delivered
• Number of late deliveries
• Hold time per incoming call
• Ave. temperature per hour
• Minutes to board plane
• Quantity of gas in tank
• Length of shaft
• Width of chips (microns)
• Number of calls on hold past 30 secs
• Hours with over 25°C
• Delayed boarding incidents
• Tank Empty/Full
• Shafts longer than 30 cm
• Out-of-spec. chips
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Select what to measure• How do our customers evaluate our
service/products?• What key questions are we trying to answer?• What data will give us the answer?• What Output or Service Requirements will help us
gauge performance to customer needs?
Note: You can’t measure everything, thus you have to select your optimal performance measures which are a balance between what is feasible and what is valuable.
71
Develop Operational Definitions• How can we clearly describe the factor/thing
(attribute or characteristics) we’re trying to track or count?
• If different people gather the data, will they interpret things in the same way?
• How can we test our definitions to make sure they’re air-tight?
Operational Definition or Op Def is a clear, understandable and unambiguous description of what is to be measured or observed so that everyone can operate, or measure, consistently on the basis of definition.
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Identify Data Sources• Where can we find or observe data to provide the measure?• Is past experience (or “historical” data) valid?• Is the data in our information system accessible and in a
usable format?• Can we afford (the time, money, disruption) to gather data?
Note: Your most important considerations are to ensure that the source you choose - or can get hold of - has accurate data and represents the process, product or service you want to measure.
73
Prepare a Collection & Sampling Plan (1)
• Who will gather and/or compile the data?• What forms, tools or instruments will they need
to capture & organize the data?• What other information will be needed to be able
to analyze the data effectively?• How many observation or items will we need to
count to get accurate measures? • How often will we need to do measures?
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Prepare a Collection & Sampling Plan (2)
• How can we ensure that the data we get are representative?
Note: Sampling is a process “snap shot”’. It means using some of the items in a group or process to represent them all. Population statistics is different from Process statistics & efforts must be exerted to differentiate between the two. The more you measure, & the better you get to know the characteristics of what you're measuring, the better your sample decisions can be.
75
Implement & Refine Measurement• Can we test out our measures before going into full -fledged
implementation?• How will we train the data collectors?• How will we monitor the data gathering?• What issues may arise (or have arisen) & what can we do
about them?Notes: Accuracy of measurement is of utmost importance. However, the
measurements must also be repeatable (results are consistent over repetitions), reproducible (other machines or people will yield the same results), and stable (accurate over time). This is known as “Gage R& R”.
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Workshop # 3 - Defects Counting
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Develop Baseline Defect Measures & Identify Improvement Opportunities
78
Key Concepts of Defect-Base Measurement
Unit - An item being processed, or the final product or service being delivered to the customer - a car, a mortgage loan, a hotel stay, a bank statement, etc.
Defect - A failure to meet a customer requirement/performance standard - a leaky crankcase, a delay in closing the mortgage loan, a lost reservation, a statement error, etc.
Defective - Any unit that contains a defect. Hence, a car with one defect is, technically, just as “defective” as a car with 15 defects.
Defect Opportunity - Since most products or services have multiple customer requirements, there can be several chances or opportunities to have a defect.
79
Defective & Yield Measures
Proportion Defective = Number of Defectives
Number of Units Produced
Final Yield = 1 - Proportion Defective
Defect per unit (DPU): the number of defects of all types, over the total number of units sampled
DPU =Number of Defects
Number of Units
80
Determining Defect Opportunities
1. Develop a preliminary list of defect types
2. Determine which are the actual, customer-critical, specific defects.
3. Check the proposed number of opportunities against other standards.
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Guidelines for Figuring Opportunities
1. Focus on “standard” problem areas.
2. Group closely related defects into one opportunity.
3. Make sure the defect is important to the customer.
4. Be consistent.
5. Change only when needed.
82
Calculating Opportunity-Based Measures (1)
Example 1: 52 defects, 250 trans. units, 4 defect opportunities/unit
Example 2: 99 defects, 750 microchips, 150 defect opportunities
1. Defect per Opportunity or DPO.
DPO =Number of Defects
# of Units x # of opportunities
= 0.052 DPO 52 defects
250 unit x 4 opportunities
= 0.00088 DPO99 defects on microchips
750 chips x 150 opportunities/chip
83
Calculating Opportunity-Based Measures (2)
2. Defects per Million Opportunities or DPMO. How many defects would arise if there were one million opportunities? In manufacturing environments, DPMO is often called PPM.
Example 1: Transformer units have 0.052 DPO DPMO: 0.052 x 106 = 52,000 DPMO
Example 2: Microchips have 0.00088 DPO DPMO: 0.00088 x 106 = 880 DPMO
84
Calculating Opportunity-Based Measures (3)
3. Sigma Measure or Score - this is arrived at converting your DPMO number to Sigma score by using a conversion table.
Example 1: transformers : 52,000 DPMO = 3.1 sigma (from table)
Example 2: microchips: 880 DPMO = 4.63 sigma (from table)
85
Measurement Process Summary
• Select what to measure
• Develop operational definitions
• Identify data sources
• Prepare a collection & sampling plan
• Implement & refine measurement
86
Workshop # 4 - Second Production Run
87
4. Prioritize, analyze & implement improvements
• Select improvement projects & develop Project Rationale
• Analyze, develop and implement root cause-focused solution(s)
• Design/redesign and implement effective new work process
DM
AIC
MD
ADV
88
PROBLEM STATEMENT STRUCTURE
What?
•Which process is involved?•What is wrong?•What is the gap or opportunity?
Where?
When?
•Where do we observe the problem/gap?
[ ] department [ ] region [ ] etc.•When do we observe the problem/gap?
[ ] time/day/mo./hr [ ] before/after/during [ ] etc.
How Big?
•How big is the problem/gap/opportunity?•How do we measure it?
Impact? •What’s the impact of the problem/opportunity?•What are the benefits of action/consequences of inaction?
89
Elements of a Goal Statement
• A description of what’s to be accomplished.
• A measurable target for desired results.
• A project deadline &/or timeframe for results
90
Problem Solving Tools
• Pareto Analysis
• Cause & Effect Diagram ( the 6M)
• Process Mapping
• Histogram
• Run Chart or Time Series Plot
• Scatter Plot or Correlation Diagram
• Etc.
91
The 6Ms of the Process
P.S.
MAN MACH
METMEASMN
MAT
92
Forms of Process Waste
• Overproduction
• Inventory
• Transportation
• Motion
• Waiting
• Overprocessing
• Producing failures
93
Key Steps to DMAIC Solution• Generate solution ideas. Use brainstorming,
commonsense, how-how diagram, best practices analysis, expert input, etc. to create a broad array of possibilities to deal with the root cause.
• Narrow options & create “Solution Statements”. Refine the ideas into workable approaches that can be implemented in the process/business.
• Select the solution to be recommended/implemented. Review your “short list” of options & identify the solution to be implemented to achieve your goal.
105
The Work PlanActivities Gantt & Deadline Who Resource rqmt Output % Completion
106
Design/redesign or DMADV Cycle
• Essentially the same as the DMAIC
• Exponential (instead of incremental) improvement
• The organization has to take risk
• The Six Sigma Team may have to challenge the limits
• The team should always go back to the basic question: ”What process will efficiently bring out value that our customer pays for ?”
107
Value Analysis
• Value Adding - the process or activity which the customer will be happy paying for
• Non- Value Adding - process or activity that adds to costs but not value to the customer (e.g. storage, transportation, temporary placement, inspection, having to use discretion, redundant process, waiting etc.)
• Value-Enabling - activities that allow you to do work for the customer more quickly or effectively. (e.g. encoding information in the database, referring to tables, using work aids, using tools & jigs to pre-work set up, etc.)
108
Steps in the Improve Phase
Confirm/Adjust Scope; Develop High-Level Map
Create Design Concept/Ideas
Build Detailed “Should-Be” Design
Assess Design per Operating Criteria
Test, Troubleshoot, Sell & Improve Design
Pilot the New Process
Launch Complete Process; Monitor for ImprovementImplement
Refine
Design
109
6 Sigma Design
• Determine the customer requirements and specifications
• Design the product so that it is inside the necessary operating parameters of the 6 - Sigma limits
• The product design accounts for the variability of the production process
110
5. Expand & integrate the Six Sigma System
• Implement ongoing measures & actions to sustain improvement
• Define responsibility for process ownership & management
• Execute “closed-loop” management & drive to Six Sigma
$$$
111
Build Solid Support for the Solutions
• Work with those who manage the process
• Use a Storyboard with facts and data
• Document and standardize successful solutions
• Treat the people managing and using the new process as your customers
• Create a sense of purpose and enthusiasm
112
Closed-Loop Six Sigma Management
• Create an internal and external feed back & control system
• Process owner understands and is updated on the bottom line impact of the improved or redesigned process
• Display score cards
• Customer report cards
113
Workshop #5 - Improvement Mode
114
Roles in Six Sigma (1)• Six Sigma Leadership Team - composed of the top
executives serves as Steering Committee• Sponsor or Champion - a senior manager who
oversees an improvement project• Six Sigma Director - implementation leader, does
most of the administrative work• Six Sigma Coach - a consultant or technical expert
who provides assistance to Process Owners or Six Sigma Improvement Teams
115
Roles in Six Sigma (2)• Project or Team Leader - an individual who takes
primary responsibility for work & the results of a Six Sigma project
• Team Member - provides the extra brains and muscle behind the project efforts
• Process Owner - the person who receives the “handoff” from Six Sigma Improvement Teams or becomes the owner of the new & newly designed processes. The Sponsor and the Process Owner may be the same person.
116
Six Sigma Leadership Team (1)
• Planning and marketing• Establish the roles & infrastructure of the Six Sigma
initiative• Select specific projects & allocate resources• Review the progress of various projects & offer
ideas & help• Serve as sponsors of Six Sigma projects• Help quantify the impact of Six Sigma efforts on the
company bottom line
117
Six Sigma Leadership Team (2)• Assesses progress & identify strengths & weaknesses
in the effort• Shares best practices throughout the organization - &
with key suppliers & customers, where appropriate• Acts as “roadblock removers” when teams identify
seeming barriers• Applies the lessons learned to members’ own
individual management styles
118
Sponsor or Champion (1)• Sets & maintains broad goals for improvement
projects under his or her charge - including creating the Project Rationale - and ensure that they’re aligned with business priorities.
• Coaches on & approves changes in direction or scope of a project, if needed
• Finds (& negotiates) resources for projects• Represents the team to the Leadership Group &
serve as its advocate
119
Sponsor or Champion (2)
• Helps to smooth out issues & overlaps that arise between teams, or with people outside the team
• Works with Process Owners to ensure a smooth handoff at the conclusion of an improvement project
• Applies the gained knowledge of Process Improvement to his/her own management task
120
Six Sigma Director (1)• Supports the Leadership Group in its
activities, including communication, project selection, & project reviews.
• Identifies &/or recommends individuals/groups to fulfill key roles - including external consulting & training support
• Prepares & executes training plans, including curriculum selection & schedule & logistics
121
Six Sigma Director (2)
• Helps Sponsors fulfill their role as supports, advocates, & “nudgers” of the teams
• Documents overall progress & surfacing issues that need attention
• Executes the internal “marketing plan” for initiative
122
Project or Team Leader (1)
• Reviews/clarifies the project rationale with the sponsor
• Develops & updates the Project Charter & implementation plan
• Selects or helps to select the project team members• Identifies & seeks resources/information• Defines & helps others in the use of appropriate Six
Sigma tools - as well as team & meeting management techniques
123
Project or Team Leader (2)
• Maintains the project schedule & keep progress moving toward final solutions & results
• Supports the transfer of new solutions or processes to ongoing operations, while working with functional managers &/or the Process Owner
• Documents final results and create a “storyboard” of the project
124
Six Sigma Roles & TitlesGeneric RoleLeadership Team or Council
SponsorSix Sigma Director
Coach
Team LeaderTeam MemberProcess Owner
“Belt” or Other TitleQuality Council, Six Sigma
Steering CommitteeChampion, Process OwnerQuality Leader, Master
BlackbeltMaster Black Belt or Black
BeltBlack Belt or Green BeltTeam Member or Green BeltSponsor or Champion
125
Black Belts• Originated at Motorola in early 1990s• Individuals possessing special expertise in statistics &
product/process improvement• Certification & training was developed jointly by
Motorola, Texas Instruments, IBM & Kodak during the early the Six Sigma years
• Now there is no “official” job description or certification for Black Belts
• It is not uncommon to think that a Master Black Belt is a trainer while a Green Belt is a team member who hasn’t attained the Black Belt category yet.
126
Six Sigma Success
Leadership commitment. It requires serious commitment in the form of time, effort and resources. To be successful, such commitment must come first from the top executive leadership of the organization and must be practiced by everyone.
127
Six Sigma Success
• Managing with data. Proper use of data to measure, analyze, improve and control performance forms the foundation of the Six Sigma methodology.
128
Six Sigma Success
• Training and cultural change. High-caliber training is required. Disciplined implementation must follow. People at all levels have to change the way they go about doing their jobs. In short, new ways of thinking, communicating and operating must pervade the entire organization.
129
Six Sigma Organization
An organization that is actively working to build the themes and practices of Six Sigma into its daily management activities, and is showing significant improvements in process performance and customer satisfaction.
130
Investments in Six Sigma
• Leadership
• Training, consulting and meetings
• Measurements
• Payroll of full time Six Sigma personnel
• Implementation of solutions
131
A MODEL SIX SIGMA TRAINING CURRICULUM (1)
Training Component
Orientation to the Six Sigma Concepts
Key Content
Basic Six Sigma Principles: review of business need for Six Sigma: brief practice &/or simulation: overview of roles & expectations
Audiences
All
Length
1-2 Days
Leading & Sponsoring Six Sigma Efforts
Role requirements & skills for Leadership Council & Sponsors: Project Selection: Reviewing team projects
Business Leaders, Implementation Leaders
1-2 Days
132
A MODEL SIX SIGMA TRAINING CURRICULUM (2)
Training Component
Six Sigma Process & Tools for Leaders
Key Content
Condensed & adapted instruction in Six Sigma measurement & analysis process/tools
Audiences
Business Leaders, Implementa-
tion Leaders
Length
3-5 Days
Leading Change Concepts & practices for setting direction,promoting & guiding organizational change
Business Leaders, Implementation Leaders, Coach/Master Black Belts, Team Leaders/Black Belts
2-5 Days
133
Business Leaders, Coaches/Master Black Belts, Team Leaders/Black Belts, Managers/Green Belts, Team Members
A MODEL SIX SIGMA TRAINING CURRICULUM (3)
Training Component
Six Sigma Improvement Basic Skills
Key Content
Process Improvement, Design/Redesign, & core measurement & improvement tools
Audiences
Team Leaders Black Belts, Managers/Green Belts,Team Members, Project Sponsors
Length
6-10 Days
Collaboration & team Leadership Skills
Skills & methods for developing consensus, leading discussions, conducting meeting, managing disagreement
2-5 Days
134
A MODEL SIX SIGMA TRAINING CURRICULUM (4)
Training Component
Intermediate Six Sigma measurement & analytical tools
Key Content
Technical skills for more complex project challenges; sampling & data collection; Statistical Process Control; Test of Statistical Significance; Correlation & Regression; basic design of experiments; etc.
Audiences
Coaches/Master Black Belts, Team Leaders/Black Belts
Length
2-6 Days
135
A MODEL SIX SIGMA TRAINING CURRICULUM (5)
Training Component
Advanced Six Sigma Tools
Key Content
Modules in specialized skills & tools: Quality Function Deployment;Advanced Statistical Analysis Advanced DOE; Taguchi Methods; etc.
Audiences
Coaches/Mater Black Belts, Internal Consultants
Length
6-10 Days
Process Management Principles & Skills
Defining a core or support process; identifying critical Outputs, Requirements, & Measures; Monitoring & Response plans
Varies by Topics
Process Owners, Business Leaders, Functional Mangers
136
Introducing Six Sigma to your Company
• How will you introduce Six Sigma to your company?
• Who will be your targeted audiences?• Who will be your allies?• What activities will you undertake, in what
sequence, and with what target dates?• Do you anticipate resistance? From whom?
How will you overcome it?
137
END