Post on 05-Jan-2016
Customer Expectations
Standards Certifications Inspections Packaging Others
Standards
Identify applicable product standards Identify applicable test standards Understand and implement
Certifications
Quality Management System (ISO 9001:2008) Environmental Management System (ISO 14001:2004) OHSAS 18001:2000 CE Mark
Inspections
Second party inspection Third party inspection Self inspection
Packaging
Proper packaging material Export worthy packaging Usage of symbols Counter presence Packaging cost
Others
Cleanliness Finish Compliance Timiliness Variation
Methods
Benchmarking Reliability Studies FMEA QFD Six Sigma
Six SigmaSix Sigma
What is Six Sigma?
1. Philosophy: We should work smarter, not harder.
2. Business strategy: We gain a competitive edges in Quality, Cost, Customer Satisfaction.
3. Statistical measurement:We measure defect rates in all processes through an expanding statistical concept.
What is Six Sigma?
Sigma is a statistical measure of variation from the average
For a manufacturing process, the sigma value is a metric that indicate how well that process is performing.
The value of 1 sigma is one standard deviation from the mean.
Six Sigma Approach
Combines some of the best technique of the past with recent breakthroughs in management thinking and plain old common sense.
The term ‘Six Sigma’ is a reference to a particular goal of reducing defects to near zero.
Benefits:
The goal of Six Sigma is to increase profits by eliminating variability, defects and waste that undermine customer loyalty.
Goals of Six Sigma
To achieve Zero Defect (3.4 PPM) in all outputs of the company through:
a) Measurement of defects in six sigma scale
b) Process re-design to improve capability
c) Involvement of all Employees
Six Sigma Belts:
Black Belt: Someone who either coaches or actually leads a Six Sigma team.Master Black Belt: A person who coaches a large number of Six Sigma teams.Green Belt: Employees who have received basic Six Sigma training.
Calculating Sigma
Step 1: Calculating Defects per Unit (DPU)
DPU = Total number of defects Total number of units
Calculating Sigma
Step 2: Calculating Defects Per Million Opportunities for error (DPMO)
DPMO = DPU X 1,000,000No. of opp. for error
Calculating Sigma
Step 3: Correlate the DPMO to the chart showing correlation between “defects per million opportunities” and sigma levels.
Sigma and it’s DPMO
Sigma (σ) value Defects per million opportunities
(+/-) 2 308, 537.0
(+/-) 3 66, 810.0
(+/-) 3.5 22, 750.0
(+/-) 4 6, 210.0
(+/-) 4.5 1,350.0
(+/-) 5 233.0
(+/-) 5.5 32.0
(+/-) 6 3.4
SIGMA CONVERSION CHARTSIGMA CONVERSION CHART
Tolerance
UCL
USL
LCL
LSL
X
+3σ
+6σ
-3σ-6σ
Case ExampleSTEP
ACTION EQUATION
CALCUL.
1. How many units were put through the Process?
-- 1283
2. How many came out error free?
-- 1138
3. Compute the yield of the process.
step 2/ step 1 0.8870
4. Compute the defect rate. 1 – step 3 0.113
5. Compute the number of potential things that could create a defect.
N number of CTQs (Critical
To Quality parameters)
24
Case ExampleSTEP
ACTION EQUATION
CALCUL.
6. Calculate the defect rate per CTQ characteristics
Step 4/ step 5 0.0047
7. Compute the defects per million opportunities
Step 6 X 1,00,000
4709
8. Convert the DPMO into sigma value using the sigma conversion chart
-- 4.1 sigma
9. Draw conclusions Slightly above
average performanc
e
Six Sigma Tools:
There are two six sigma methodologies:
DMAIC (define, measure, analyze, improve, control)DMADV (define, measure, analyze, design, verify)
Six Sigma Tools:
For existing processesD DefineM MeasureA AnalyzeI ImproveC Control
Six Sigma Tools:
For new processesD DefineM MeasureA AnalyzeD DesignV Verify
The Journey
Six Sigma aims at continual improvement through the journey
starting from the existing sigma level, gradually moving towards six sigma
level and beyond.