Outline
What is Six Sigma?
Phases of Six Sigma
- Define
- Measure
- Evaluate / Analyze
- Improve
- Control
Design for Six Sigma
Green Belts & Black Belts
What is Six Sigma?
- Reduces dependency on “Tribal Knowledge” – Decisions based on facts and data rather than opinion
- Attacks the high-hanging fruit (the hard stuff) – Eliminates chronic problems (common cause variation) & Improves customer satisfaction
- Provides a disciplined approach to problem solving – Changes the company culture
- Creates a competitive advantage (or disadvantage)
- Improves profits!
What Sigma is Not
- Just about statistics
- A quality program
- Only for technical people
- Used when the solution is known
- Used for “firefighting”
How good is good enough?
How can we get these results?
13 wrong drug prescriptions per year
- 10 newborn babies dropped by doctors/nurses per year
- Two shorts or long landings per year in all the airports in the U.S.
- One lost article of mail per hour
Six Sigma as a Metric
Effect of 1.5 Sigma Process Shift
3 Sigma Vs. 6 Sigma
Sigma and PPM
Six Sigma as a Philosophy
The fact is, there is more reality with this [Six Sigma] than anything that has come down in a long time in business. The more you get involved with it, the more you’re convinced.
Six Sigma Tools
Six Sigma Principles
- Customer Focus
- Leadership
- Innovative and Proactive
- Boundary-less
- World Class Quality
- Fact Driven
- Process Management
Problem Solving Methodology
Project Charter
- Business Case
- Problem Statement
- Goal Statement
- Team Members
- Team Role & Responsibility
- Action plan VS. budget
Define Phase
- Define Process
- Define Customer requirement
- Prioritize Customer requirement
- SIPOC Model
- Customer Survey
- Customer Requirement Analysis
- QFD
- Standard / Regulation Review
- Kano Analysis
- CTQ Diagram
- Literature Review
- Project Review
- Project Charter
- Problem Statement
- Goal Statement
- Scope of process
- Prioritized customer requirement
Measure Phase
- Identify measurement and variation
- Determine data type
- Perform measurement system analysis
- Perform data collection
- Perform capability analysis
- Effectiveness of existing process
- Efficiency of existing process
- Calculate Sigma Level
- Calculate Cost of poor quality
- SIPOC-RM
- CTQ-R
- Check Sheet
- MSA
- Basic Statistics
- Project Review
- Customer satisfaction
- Effectiveness of process
- Efficiency of process
- Base line sigma (Yield, DPMO, CPk)
- Cost of poor quality
Assignable Cause
- Outside influences
- Black noise
- Potentially controllable
- How the process is actually performing over time
Common Cause Variation
- Variation present in every process
- Not controllable
- The best the process can be within the present technology
Evaluate / Analysis Phase
- Data Analysis
- Process Analysis
- Formulate Hypothesis
- Test Hypothesis
- Run chart
- Pareto chart
- Relation Diagram
- Process Analysis
- Hypothesis Testing
- Chi-square
- Project Review
- Validated root cause statement
- Histogram
- CE Diagram
- T-Test
- ANOVA Correlation Regression
Improvement Phase
- Generate Improvement alternatives
- Validate Improvement
- Update FMEA
- Perform Cost/Benefit analysis
- Brain Storming
- Creativity
- Criteria Weighting
- Change Management tools
- DOE
- Cost/Benefit Analysis
- Project Review
- Validated pilot study
- Result of cost benefit analysis
- Plan of control phase
Design of Experiments (DOE)
- To estimate the effects of independent Variables on Responses.
- Terminology – Factor – An independent variable, Level – A value for the factor., Response – Outcome
Why use DOE ?
- Shift the average of a process.
- Reduce the variation.
- Shift average and reduce variation
DOE Techniques
- Full Factorial
- 24 = 16 trials
- 2 is number of levels
- 4 is number of factors
- All combinations are tested
- Fractional factorial can reduce number of trials from 16 to 8 – Fractional Factorial, Taguchi techniques, Response Surface Methodologies, Half fraction
Control Phase
- Develop control strategy
- Develop control plan
- Update procedure and training plan
- Monitor result
- Correct action as needed
- Project Review
- Procedure
- Work instruction
- Full implementation
- Control chart of result
Project Closure
What is Design for Six Sigma (DFSS)?
DFSS Methodology & Tools
Design for Six Sigma
- Pre-DEFINE Phase
- Introduction to Six Sigma
- DFSS / New Product Introduction (NPI) Process – Strategic vision, Logical chain of product concepts, Product evolution road map, DEFINE Phase
- Establish Design Project
- Financial Analysis
- Project Management and Risk Assessment
MEASURE Phase
- Establish CTQ’s and CTI’s
- Design problem documentation
- Design expectations
- Probability, Statistics, and Prediction
- MSA (Variables, Attribute and Data quality)
- Process Capability (Variables and Attribute)
- Risk Assessment
- Failure prediction
- Design Scorecard
ANALYZE/HIGH-LEVEL DESIGN Phase
- Develop Design Alternatives
- Description of design options (alternatives)
- Analysis of design alternatives for technological barriers and contradictions
- Develop High Level Design (VA/VE)
- Multi-Variable Analysis
- Confidence Intervals & Sampling
- Hypothesis Testing
- Evaluate High Level Design
- Failure analysis and prediction
DETAIL DESIGN Phase
- Risk Assessment Failure analysis
- Taguchi Methods
- Tolerance
- DOE with RSM
- DETAIL DESIGN Phase (cont’d)
- Reliability and Availability
- Non-Parametric Statistics
- Simulation with Monte Carlo Methods
- Design for Manufacturability/Assembly
- DVT/Testability
- Design Scorecard
- Concurrent Engineering
- Software Engineering Tools (CMM, CASE)
VERIFY Phase
- Design for Control
- Design for Mistake Proofing
- Statistical Process Control (SPC)
- MVT
- Transition to Process Owners
- Logical sequence of new scenarios
- Strategic knowledge base and patent portfolio
- Targeted competitive intelligence
- New product evolutionary stages
- Project Closure
- Pilot Testing
- Full-Size Scale Up and Commercialization
- Design Information and Data Management
- Lean Manufacturing
Green Belts & Black Belts
GE has very successfully instituted this program
- 4,000 trained Black Belts by YE 1997
- 10,000 trained Black Belts by YE 2000
You haven’t much future at GE unless they are selected to become Black Belts
Kodak has instituted this program
- CEO and COO driven process
- Training includes both written and oral exams
- Minimum requirements: a college education, basic statistics, presentation skills, computer skills
Other companies include:
- Allied Signal
- IBM
- Navistar
- Texas Instruments
- ABB
- Citibank
It is reasonable to guess that the next CEO of this company, decades down the road, is probably a Six Sigma BB or MBB somewhere in GE right now…