© absl power solutions 2007 © stm quality limited stm quality limited six sigma total quality...
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© ABSL Power Solutions 2007© STM Quality Limited
STM Quality Limited
Six Sigma
TOTAL QUALITY MANAGEMENT
6
© STM Quality Limited
STM Quality Limited
What is ‘Six Sigma’?
Six Sigma is a quality measure & improvement program developed by Motorola.
It is used to reduce product defects, improve quality and increase profitability.
© STM Quality Limited
STM Quality Limited
What Does Sigma Mean?
Sigma is a Greek letter and is used in statistics to denote variation, or ‘standard deviation’.
To control a process to the point of six sigma means to control defects to 3.4 per million items.
© STM Quality Limited
STM Quality Limited
The Use Of Six Sigma
By identifying factors which are critical to quality, we can:
Reduce process variation;Improve capabilities;Increase stability;Work towards ZERO DEFECTS.
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STM Quality Limited
Zero Defects
If we can measure how many defects we have in any given process, then we can systematically work towards eliminating them and get as close as possible to zero defects.
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STM Quality Limited
Key Elements of Quality
1. The Customer.2. The Process.3. The Employee.
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STM Quality Limited
1. The Customer
Defines quality;Expects performance, reliability,
competitive price, on time delivery, service, correct transaction processes, etc.
Being good is not enough – customers need to be delighted!
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STM Quality Limited
2. The Process
There is a need for us to look at our business from the customer’s perspective.
That is, to look at our processes from the outside in.
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STM Quality Limited
3. The Employee
Lets put it simply:
PEOPLE CREATE RESULTS!
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STM Quality Limited
The DMAIC Model
At the heart of Six Sigma is a systematic method for analyzing & improving business process, called DMAIC.
The DMAIC model includes five phases.
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STM Quality Limited
Five DMAIC Phases
Define opportunities;Measure performance;Analyse opportunity;Improve performance;Control performance.
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STM Quality Limited
DMAIC Phases - Define
Measure performance
Various tools can be used once we have a measurement plan.
Benchmarking, S.P.C., calculation of process sigma, R & R studies, etc.
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STM Quality Limited
DMAIC Phases - Measure
Define opportunities
This is the step we take to find exactly what the requirement, measure, or concern is.
Without defining, we cannot perform the other elements!
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STM Quality Limited
DMAIC Phases - Analyse
Analyse
Once we have measured data we can analyse it using cause & effect analysis; financial assessment, value added analysis etc.
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STM Quality Limited
DMAIC Phases - Improve
Improve
Having analysed our data we can take steps to improve the process using Design of Experiments, F.M.E.A., Poka-Yoke, etc.
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STM Quality Limited
DMAIC Phases - Control
Control
Once we have made process improvements we need to control the process using Kaizan, Control charts, 5c etc.
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STM Quality Limited
The DMAIC Process - Example
Lets look at an example:
A company is having parts failing inspection after machining.
Lets see how the DMAIC process could be used…
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STM Quality Limited
The DMAIC Process – Example: Define
Define:Inspection are rejecting high
number of parts after final machining.
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STM Quality Limited
The DMAIC Process – Example: Measure
Measure:Yield obtained; Number of defects in total
measured so that standard deviation can be defined.
© STM Quality Limited
STM Quality Limited
The DMAIC Process – Example: Analyse
Analyse:Operators;Material;Identified variables that could
impact production;Different experiments conducted;Range of acceptable levels
determined.
© STM Quality Limited
STM Quality Limited
The DMAIC Process – Example: Improve
Improve:Operating instructions changed; Production levels bought into line
with capacity;Final production yield increased!
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STM Quality Limited
The DMAIC Process – Example: Control
Control:Control charts introduced for each
machine; Corrective Action Plan provided for
defects.
© STM Quality Limited
STM Quality Limited
Six Sigma
So as can be seen from the example, the DMAIC process was applied.
Remember that there may not be a ‘quick fix’ and that resources need to be applied to a problem.
© STM Quality Limited
STM Quality Limited
Six Sigma Belts
Experts at Six Sigma disciplines are often referred to as ‘Master Black Belts’.
These experts often train others in the disciplines, being ‘Black Belts’ and ‘Green Belts’.