Presentation

Title: Apply Six Sigma with ease

Presented

on 2nd Feb 2015

@ 3rd Annual Lean Conference,

AMA, Ahmedabad avci-lean.com

APPLY SIX SIGMA (6σ) WITH EASE

History of Six Sigma (6σ)

• In 1986 Bill smith, Seniors Engineer and scientist introduces concept of Six Sigma

• Bill smith Known as “ Father of Six Sigma”

• In 1995, Jack Welch introduced Six Sigma at GE

μ

σ

What’s in a name? • Sigma is the Greek letter representing the standard

deviation of a population of data

• Sigma is a measure of variation

(the data spread)

What is Six Sigma ?

A

Methodology? What is

Six Sigma?

A

philosophy?

A

metric?

A

Management

System?

What is Lean Six Sigma?

• Goal – Eliminate waste and increase process speed

• Method

– Genchi Genbutsu– Go and See the workplace (Gemba)

– Kaizen (Change for better) workshops

What is Lean ?

What is Lean Six Sigma?

• Goal – Reduce variation to improve performance on CTQs

(Variation means system does not produce same result each time)

• Method – DMAIC, DMADV,DFSS approach

7

What is Six Sigma ?

Normal Distribution Curve

µ + -

- 1σ + 1σ

- 2σ + 2σ

68.26%

- 3σ + 3σ

+ 4σ

- 5σ

95.44%

99.73% 99.9937%

99.99943%

+ 5σ

- 6σ + 6σ 99.999998%

- 4σ

Lower Spec

Upper Spec

Sigma % Good % Bad DPMO

1 30.9% 69.1% 691,462

2 69.1% 30.9% 308,538

3 93.3% 6.7% 66,807

4 99.38% 0.62% 6,210

5 99.977% 0.023% 233

6 99.9997% 0.00034% 3.4

Defect Per Million Opportunity (DPMO)

-6σ -5σ -4σ -3σ -2σ -1σ μ +1σ +2σ +3σ +4σ +5σ +6σ

? times σ

LSL

Mean

1σ

USL

Question - How many times of standard

deviation (σ) is specification limit to

mean?

Answer – Same as sigma level for the

process (Z value)

What is Six Sigma performance?

Your process is performing at sigma level of six if

the difference between mean and specification

limit is six times the standard deviation

Is it feasible to eliminate the inspection of Y, if X’s are controlled well?

•

•

•

•

•

•

•

Y

Dependent

Output

Effect

Symptom

Monitor

Response

•

•

•

•

•

•

•

X1 . . . XN

Independent

Input

Cause

Problem

Control

Factor

To get results, should we focus our behavior on the Y or X ?

f (X) Y=

Data Driven Approach

How Six Sigma Process Follows?

• Identify customer issues which generally follows timely delay, high cost, defect etc…

• Internalized as performance measures such as e.g. Cycle time, defect rate etc.

• Target performance levels are established and then

company seek to perform around this targets with minimal variation

THE DMAIC METHOD

IMPROVE

CONTROL

MEASURE

ANALYZE

5

2

3

4

DEFINE

1

Projects Identification Method

VOC ANALYSIS (Problem identification based on customer’s voice)

VOB ANALYSIS (Problem identification based on Business problems)

COPQ (Problem identification based on cost of poor quality i.e. Process Defects )

Identification of CTQs

List of problems/projects of organization on the basis of Criticality, Out come , Time line

Phase 1: Define

Phase 2: Measure

• Goal

– Focus the improvement effort by gathering information on the current situation

• Output

– Data that pinpoints problem location or occurrence

– Baseline data on current process sigma

– A more focused problem statement

IMPROVE

CONTROL

ANALYZE

5

3

4

DEFINE

1

MEASURE

2

DATA COLLECTION

• The system to collect information is already established.

• Find the data which supports the defined problem

• Find out the data stream wise/ product wise etc..

Data type:

• Attribute data or Discreet : Value of countable quality characteristics Example - Number of Defects, Number of Defectives.

• Continuous data or Variable data : Value of measurable quality

characteristics

Examples - Strength (kg/cm2), weight (kg) , length (cm), temperature (° C), time (sec)

Phase 3: Analyze

IMPROVE

CONTROL

MEASURE

ANALYZE

5

2

3

4

DEFINE

1

• Goal

– Identify deep root causes and confirm them with data

• Output

– A theory that has been tested and confirmed

Phase 4: Improve

• Goal – Develop, pilot, and

implement solutions that address root causes

• Output – Identification of

planned, tested actions that should eliminate or reduce the impact of the identified root causes

CONTROL

MEASURE

ANALYZE

5

2

3

DEFINE

1

FMEA IMPROVE

4

Solutions

• Improvement team created with members of Quality, Production, Engineering and R&D areas to propose and evaluate ideas

• Brainstorming tool was used to gather ideas on how to solve the problems identified

• Ideas were evaluated per following criteria: feasible, high impact, easy, low cost, and quick

• Following tables summarizes solutions agreed by consensus of the improvement team

Phase 5: Control • Goal

– Use data to evaluate both the

solutions and the plans

– Validate that all changes adhere to all

operating company change control, and compliance requirements

– Maintain the gains by standardizing processes

– Outline next steps for on-going improvement

• Output

– Before-and-After analysis

– Monitoring system

– Completed documentation of results,

learning, and recommendations

IMPROVE

CONTROL

MEASURE

ANALYZE

5

2

3

4

DEFINE

1

Standardization

– All new tooling, processes, clarifications, and visual aids documented

– Creation of MOPXXX with all the quality criteria for Variable Lasso Deflection and Contraction performance.

Monitoring

Work Orders Built

Yield Goal

Scrap Produced

Yield Actual

I-MR Charts of Burst Tester

Burst Values

Ind

ivid

ua

l Va

lue

302928272625242322212019181716151413121110987654321

115

110

105

100

_X=105.88

UCL=113.76

LCL=97.99

Observation

Mo

vin

g R

an

ge

302928272625242322212019181716151413121110987654321

10

5

0

__MR=2.97

UCL=9.69

LCL=0

Universal Tray Packaging (CA Sealer)

In-H20

Burst Values

Ind

ivid

ua

l Va

lue

302928272625242322212019181716151413121110987654321

110

105

100

95

_X=100.72

UCL=109.68

LCL=91.76

Observation

Mo

vin

g R

an

ge

302928272625242322212019181716151413121110987654321

12

8

4

0

__MR=3.37

UCL=11.01

LCL=0

Universal Tray Packaging (Juarez Sealer)In-H20

Thank You