Accelerating the Six Sigma Learning Process using ... the Six Sigma Learning...113.0 We i g h t 11.0...
Transcript of Accelerating the Six Sigma Learning Process using ... the Six Sigma Learning...113.0 We i g h t 11.0...
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_________________________________________________________________ABI Associates, Inc.
All Rights Reserved , ABI Associates, Inc. 2006
Accelerating the Six Sigma Learning Process usingStatgraphics Centurion
ABI Associates, Inc.
Terry Russell Dir. of Mgmt. Systems (513) 304-0384 [email protected]
George Dyson Dir. of Engr. Statistics(513) 919-3823 [email protected]
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_________________________________________________________________ABI Associates, Inc.
All Rights Reserved , ABI Associates, Inc. 2006
Statgraphics CenturionTM and ABI Associates, Inc.
Can HELP Your Business INCREASE PROFIT!
Statgr
aphic
s
Centu
rion
AcceleratingSix Sigma
$
• Statgraphics Centurion includes the frameworkfor Six Sigma Implementation
• Statgraphics Centurion & ABI –the perfect linkfor Six Sigma Training & Application
• ABI applies Statgraphics Centurion with proven methods for your business
• ABI applies Over 50 years of combined Engineering / Management Expertise
ABIAssociates
Inc
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_________________________________________________________________ABI Associates, Inc.
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ABI is Applied Business Improvement
• First and foremost, we listen to the Voice of the Customer…… to Customize our training for you
• Generally, we start with our traditional Six Sigma Executive Overview
• Black Belt or Green Belt Training is our main focus
• Statgraphics is the key ingredient……to Reinforce & Simplify our Training
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_________________________________________________________________ABI Associates, Inc.
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Six Sigma is ….
….an Improvement System Focusedon Driving Business Success
• Customer focused business strategy
• A disciplined data-driven approach for eliminating defects
• A statistical measurement - 3.4 DPMO
• A dedication to meeting customer requirements
• A philosophy, culture change for greater customer
satisfaction
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_________________________________________________________________ABI Associates, Inc.
All Rights Reserved , ABI Associates, Inc. 2006
Why Six Sigma Works
• Customer and Process Focus
• Senior Management Involved
• Disciplined Approach Used
• Short Project Completion Times (3 to 6 months)
• Clearly Defined Measures of Success
• Infrastructure of Trained Individuals (Black Belts, Green Belts)
• Sound Statistical Approach Used
• Bottom Line Results
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_________________________________________________________________ABI Associates, Inc.
All Rights Reserved , ABI Associates, Inc. 2006
Six Sigma Business Successes
• Cost Reduction
• Market Share Growth
• Defect Reduction
• Culture Change
• Productivity Improvement
• Customer Relations Improvement
• Product and Service Improvement
• Cycle - Time Reduction
Six Sigma Goal is Business ImprovementSix Sigma Goal is Business Improvement
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_________________________________________________________________ABI Associates, Inc.
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Motorola’s Early Experience With Six Sigma
• Five-fold growth in sales• Profits increased 20 percent per year• $14 billion in cumulative savings• Stock price gains compounded at 21% annual rate
Motorola set the original Six Sigma BenchmarkMotorola set the original Six Sigma Benchmark
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_________________________________________________________________ABI Associates, Inc.
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After Motorola……….
Many other Companies and Industries have Embraced Six Sigma achieving Greater Customer Satisfaction and Improved Profitability
• Healthcare
• Education
•Government
• Other Service- IT
• Texas Instruments
• GE
• Allied Signal/Honeywell
• Black and Decker
• DuPont
• Caterpillar
• Polaroid
• Boeing
• Federal Express
• Sony
• Toshiba
• Nokia
And the Journey Continues!And the Journey Continues!
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_________________________________________________________________ABI Associates, Inc.
All Rights Reserved , ABI Associates, Inc. 2006
Six Sigma Success Stories
• GE (Mid 1990’s)– Jack Welch: CEO – implemented 6s in 1996 to be aligned with GE’s business needs– Creates knowledge leading to higher quality products in less time than the competition.– Significant bottom-line benefits to the company.
• The GE 1997 annual report - Six Sigma delivered more than $300 million to operating income • Medical – 10X increase in the life of CT scanner x-ray tubes• “Super Abrasives” (Industrial Diamond Business) – quadrupled their return on investment• Railcar Leasing – 62% reduction in turnaround time at repair shops. Additional 50% later.• Plastics – 300 million pounds of new capacity (“free plant”). Saved $400 million in investment.
• Other Six Sigma Success Stories– Raytheon – 25% of sales spent fixing problems at 4sigma; 1% predicted at 6sigma level.– Allied Signal – $85 million plant not needed; $30–$50 million savings per year.– Lockheed Martin – Could not solve problem by traditional methods; now saves $14k per jet.– Yale – New Haven Hospital - Measurable success in improving service levels, cost productivity
and customer satisfaction
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Variability Drives Cost
SpecificationLimitsCustomer Focused View
TargetLSL USL
Any deviation from target will result in losses
The further from target the greater the cost
Any Variation from Target will Increase CostsAny Variation from Target will Increase Costs
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_________________________________________________________________ABI Associates, Inc.
All Rights Reserved , ABI Associates, Inc. 2006
Statistically Speaking, What is Six Sigma?
• Plot Sample data as a Histogram
• Draw the Normal Distribution curve over the histogram, describedby its Mean (location) and Standard Deviation or Sigma (spread).
• The “bell shaped curve” is used to identify the probably of a defect.
• A Six Sigma level process limits defects to 3.4 per million opportunities – virtual defect-free performance.
% Defective,or p(d)
−3σ −2σ −1σ 0 1σ 2σ 3σHistogram of Data
Calculate Mean,
& Sigma
USL
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_________________________________________________________________ABI Associates, Inc.
All Rights Reserved , ABI Associates, Inc. 2006
Examples of Sigma Levels
3
4
5
6
1 putt missed per
round
1 putt missed per 9
rounds
1 putt missed per 2.33 years
1 putt missed per 163 years
1.5 misspelled words per page
in a book
1 misspelled word per 30
pages
1 misspelled word in a set of encyclopedias
1 misspelled word in all the
books in a small library
3.5 months per century
2.5 days per century
30 minutes per century
6 seconds per century
Sigma Level
Sports Spelling Time
99.9 Percent Yield (Sigma Level ~4.5) May Not be Good Enough20,000 Wrong
Drug Prescriptions per Year
25,000 Newborn Babies Dropped
per Year
2 Short / Long Landings at O’Hare
Airport per Day
500 Incorrect Surgical Operations
per Week
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_________________________________________________________________ABI Associates, Inc.
All Rights Reserved , ABI Associates, Inc. 2006
Six Sigma Savings and Cost Breakdown
• DirectRevenue (Price, Growth, Capacity)Material Cost (Price, Material Productivity, Services)Conversion Cost (Productivity, Overhead)Base Cost (Engineering, Warranty, Concessions)Other Income (Taxes)
• IndirectConversion (Productivity reductions)Base Cost (Engineering savings)
• Avoidance (Direct, Balance Sheet Plant & Equipment, Tooling)• Implementation Cost
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_________________________________________________________________ABI Associates, Inc.
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Cause and EffectInputs Determine the Output
XX
XX
XXInputs OutputY = f(X)
Key Six Sigma Concept
Process Output (Y) is Function (f) of its Inputs (Xs)Process Output (Y) is Function (f) of its Inputs (Xs)
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_________________________________________________________________ABI Associates, Inc.
All Rights Reserved , ABI Associates, Inc. 2006
The Process for DMAIC Six Sigma Projects
Define -Listening to the Voice of the Customer• Prerequisites
(Philosophy, Mgmt buy-in)• Y=f(X) Concept & Strategy• ID Team / Key Constituents • Project Statement (4 Boxer.ppt)• Process Mapping/ Risk Assessment• Quality Function Deployment (QFD)• Financial Analysis
MeasureMeasuring Current Process Health• Define Performance Standards• The Y’s (CTQ’s) & the Z’s• 7 Basic Tools (Pareto Analysis, Run
Chart, Scatter Diagrams etc.)• Fishbone Diagrams• Validate the Measurement System • Establish SPC and Process Capability• Establish Tolerance Limits
AnalyzeIdentifying important causes of the defects• Multiple Box-Whisker• Regression Analysis (y vs x)• ANOVA / Components of Variance• Hypothesis Testing• Chi Square Testing• Screening Designs
ImproveRemoving the causes of the defects• Fishbone Revisited• Sequential Design of Experiments
(DoE)• Error Proofing• Revisit Tolerance Limits
ControlMaintaining the improvements• Statistical Process Control
(reduced inspection)• Capability Monitoring• Failure Mode Effects
Analysis• Action Plans
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_________________________________________________________________ABI Associates, Inc.
All Rights Reserved , ABI Associates, Inc. 2006
Using the Six Sigma (DMAIC) Modelin Statgraphics Centurion
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_________________________________________________________________ABI Associates, Inc.
All Rights Reserved , ABI Associates, Inc. 2006
The new Statgraphics Centurion Six Sigma Menu Option - Define
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_________________________________________________________________ABI Associates, Inc.
All Rights Reserved , ABI Associates, Inc. 2006
Quality Function Deployment - The House of QualityListening to the Voice of the Customer
Low Cost Reproducible Factory Implementation/Demo. Process Verification (Proof) High Reliability (>85,000) hrs. Small Size - Light Weight Performance Expandable Meets Module Elect. Performance System Maintainability
Yie
ld
49.0438.0
Pro
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Cap
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60.0504.0
Rat
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56.0500.0
Mod
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Cos
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48.0428.0
MTB
F
22.0123.0
Fai
l Fre
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22.0123.0
Siz
e15.0113.0
Wei
ght
11.088.0
Pro
cess
Fle
xibi
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16.0122.0
Cos
t to
Mai
ntai
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21.0113.0
Ava
ilabi
lity
of A
rray
19.095.0
Prio
rity
10.010.010.010.09.08.06.05.01.069.0345.0
Our
s
2.72.92.13.12.62.43.53.63.526.4193.1
The
irs
4.05.03.23.03.32.81.82.13.528.7228.9
80%
1.3
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100
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y
$20
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85,
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hrs.
10,
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hrs.
4"x
.46"
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"
1 O
Z.
TB
D
TB
D
TB
D
Absolute weight Relative weight
InteractionsStrong PositivePositiveNegativeStrong Negative
Cus
tom
er D
eman
ds
Design Requirements
RelationshipStrong = 9.0Medium = 3.0Weak = 1.0
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_________________________________________________________________ABI Associates, Inc.
All Rights Reserved , ABI Associates, Inc. 2006
Cost of Quality for a Six Sigma Project
Cost of Quality History
CO
Q
PreventionAppraisalInt. FailureTotal COQTotal Failure
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
0
20
40
60
80
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_________________________________________________________________ABI Associates, Inc.
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Brainstorming over a Fishbone Diagram
Defects
Raw card
Short circuit
Shroud
Moisture contentTime
Temperature
Solder process
SplatterChain speed
Wave pumpHeight
FlowFlux
TemperatureSetup
Control
Inspection
Measurement
Test coverage
Inspector
Components
Wrong part
Functional failure
Missing from reelVendor
Setup
Component insertion
Wrong componentMissing component
AlignmentAutoposition
Operator
Crimp
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_________________________________________________________________ABI Associates, Inc.
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The Process Map to Understand your ProcessEarly in Six Sigma
Flow ChartProcess
1
AuditProcess
2
Problems? 3Correct
Problems 4
Collect Data 5
Analyze Data 6
In Control? 7
PlotHistogram
8
Estimate ProcessCapability
9
Capable? 10
Sort Product 11
ImproveCapability
12
Meeting 13
No
Yes
Yes
Yes
No
No
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_________________________________________________________________ABI Associates, Inc.
All Rights Reserved , ABI Associates, Inc. 2006
The new Statgraphics Centurion Six Sigma Menu Option - Measure
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_________________________________________________________________ABI Associates, Inc.
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Statgraphics & Six Sigma can take “failure to meet minimum” to a 6 sigma process
Bad Process Good Process
0 10 20 30 40 50
0
2
6
8
4
10
LSL Nominal
100% Defective(failure to meet minimum)
-3s
0 10 20 30 40 50
0
2
6
8
4
10
LSL Nominal
freq
uenc
y
Response Variable Response Variable
6 sigma process-3s
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_________________________________________________________________ABI Associates, Inc.
All Rights Reserved , ABI Associates, Inc. 2006
The new Statgraphics Centurion Six Sigma Menu Option - Measure
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Which Driver has the best mileage?
1 2 3 4 5 6
Box-and-Whisker Plot
17
18
19
20
21
22M
PG
_20_
1
Driver
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_________________________________________________________________ABI Associates, Inc.
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The new Statgraphics Centurion Six Sigma Menu Option - Analyze
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X-Bar Variables Control Chart
X-bar Chart for Dia DevFromTargetX
-bar
CTR = 0.00
UCL = 17.59
LCL = -17.59
Subgroup
Target = 0
0 4 8 12 16 20-30-25-20-15-10
-505
1015202530
You Can’t Predict the Future if your Process is Out of Control!
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_________________________________________________________________ABI Associates, Inc.
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The new Statgraphics Centurion Six Sigma Menu Option - Analyze
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Defining Process Capability
+/-3 sigmaUSLLSL
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SnapStat: Capability Assessment (Individuals)
Data variable: strengthSample size = 100 Mean = 254.64
Specifications Beyond Spec. Z-ScoreUSL = 300 0.000000% 4.25Nom = 250LSL = 200 0.000000% -5.12
Long-Term Capability Short-Term CapabilitySigma = 10.6823 Sigma = 10.1637Pp = 1.56 Cp = 1.64Ppk = 1.42 Cpk = 1.49DPM = 11.03 DPM = 4.08
X Chart
Observation
stre
ngth
0 20 40 60 80 100220
240
260
280
300
254.64
285.13
224.15
Capability Histogram
strengthfre
quen
cy
200.00 250.00 300.00
200 220 240 260 280 3000
5
10
15
20
25
Range Chart
Observation
MR
(2)
0 20 40 60 80 1000
10
20
30
40
50
11.46
37.46
0.00
Probability Plot
strength
Nor
mal
Dis
tribu
tion
200 220 240 260 280 300200
220
240
260
280
300
Tolerance Chart
Observation
stre
ngth
0 20 40 60 80 100200
220
240
260
280
300
250.00
300.00
200.00
Snapstats: A Special Feature inStatgraphics Centurion forQuick Process Capability
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The new Statgraphics Centurion Six Sigma Menu Option - Improve
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Best Fit Model Selected from 27 Transformations
Plot of Fitted Model
weeks
chlo
rine
0 10 20 30 40 500.38
0.4
0.42
0.44
0.46
0.48
0.5Reciprocal -X
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The new Statgraphics Centurion Six Sigma Menu Option - Improve
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0 5 10 15 20 25 30 35 40 45
1
2
3
4
Fat (gms) UGH!
Cos
t/Vol
ume
(cen
ts)
Orville
Pillsbury
Betty Crocker
Kohls
Regular (plain)Reg+1 tbsp
Reg+2 tbspReg+3 tbsp
Reg+4 tbsp
Regular = Non-Microw ave Old Capitol Popcorn
Six Sigma Enters the World of a Science Project“Maybe Microwave Popcorn ain’t so Hot !”
X2-
X1X3
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Process Development Using Sequential Experimentation
0
10
20
30
1 2 3 4 5 6 7
Experiment No.
Res
pons
e Va
riabl
e ResponseSurface
Factorials
Screening Designs
Climbing to the peak of themountain in the fewestnumber of trials
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The new Statgraphics Centurion Six Sigma Menu Option - Control
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Detecting Small Sigma Shifts
EWMA Chart for DATA
Observation
EWM
A
CTR = 6.04UCL = 17.91
LCL = -5.84
0 20 40 60 80-6
-1
4
9
14
19
24
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ABI Six Sigma Course Offerings (using Statgraphics Version 5 or CenturionTM )
• Six Sigma Executive Overview (1/ 2 Day) $ 2,500
• Six Sigma Overview (2 Day) $ 5,000
• Six Sigma Green Belt (10 Days Total) $ 25,000 (Four x 2 Day sessions + 2 Day Project Mentoring)
• Six Sigma Black Belt (14 Day) $ 35,000 (three x 2 + two x 3 Day sessions +2 Day Project Mentoring)
• Process Understanding and Improvement (1/2 Day) $ 2,500 (1 Day also available)
• Design of Experiment – Executive Overview (1/2 Day) $ 2,500(1 Day also available)
• Design of Experiments – Introduction (1 Day) $ 2,500• Design for Six Sigma (DFSS) (Under Development)
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Six Sigma OverviewDefine / Measure / Analyze (Day 1)
• What is Six Sigma?• DMAIC Model • Project Selection • Project Charter• Team Roles and Responsibilities• Voice of the Customer• Concept Engineering• Quality Function Deployment• Using SIPOC for Process Identification • Process Mapping• Measurement System Analysis• Data Collection Methods• Understanding Variation• Fundamentals of Statistical Process Control (SPC) • Defining Process Capability• Calculating Sigma Levels /DPMO
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Six Sigma Overview
Analyze / Improve / Control (Day 2)
• Seven Basic Quality Tools for Analyzing Data• Basic Regression• Design of Experiments (DoE)• Analysis of Variance (ANOVA)• Failure Mode & Effects Analysis (FMEA)• Error Proofing• SPC for Process Control• Piloting and Implementing a Process Control Plan• Lean Enterprise / Lean Six Sigma• Reporting Project Benefits / Financial Impact • Leveraging “Best Practices”• Summary and Lessons Learned
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Six SigmaBlack Belt Training
Session 1Define2 Days
• Six Sigma Overview
• What’s In It for Me?
• DMAIC Model
• Project Selection
• Project Charter
• Team Roles and Responsibilities
• Voice of the Customer
• Quality Function Deployment (QFD)
• Process Mapping
• Using SIPOC for Process Identification
• Pareto Diagram
• Cause and Effect Diagram
• Define Phase Summary
• Statgraphics Tutorial
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Session 2Measure3 Days • Leadership Team Project Reviews
• Measurement System Analysis
• Data Collection Methods
• Understanding Variation
• Using Statistical Process Control (SPC)
• Defining Process Capability
• Calculating Sigma Levels/ DPMO/ Cycle Time
• Measure Phase Review
• Statgraphics Training
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Session 3Analyze3 Days • Leadership Team Project Reviews
• Seven Basic Quality Tools for Analyzing Data
• Linear and Multiple Regression
• Design of Experiments (DoE)
• Six Sigma DoE Exercise
• Analysis of Variance (ANOVA)
• Use of e-Tools/ Wizards
• Analyze Phase Review
• Statgraphics Training
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Session 4Improve3 Days • Leadership Team Project Reviews
• Failure Modes and Effects Analysis (FMEA)
• Error Proofing
• Design for Six Sigma (DFSS)
• Piloting Process Improvement
• Process Improvement Assessment
• Implementing Process Improvement
• Improve Phase Review
• Statgraphics Training
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Session 5Control2 Days • Leadership Team Project Reviews
• SPC for Process Control
• Process Control Plan
• Process Documentation
• Reporting Project Benefits/Financial Impact
• Leveraging “Best Practices”
• Summary and Lessons Learned
• Control Phase Review
• Lean Enterprise/ Lean Six Sigma
• Black Belt Certification Assessment
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ABI Associates
George Dyson and Terry Russell have been actively involved in both teaching and mentoring Six Sigma and Design for Six Sigma directly with domestic and International businesses. Recently Terry and George were invited to participate in teaching Six Sigma and Design for Six Sigma for General Electric.
George H. Dyson III
George Dyson is Director of Engineering Statistics for ABI Associates, Inc., a business improvement consulting practice devoted to optimizing Six Sigma training/Implementation to improve business performance.
George is also the area Six Sigma representative for StatPoint, Inc., the developer of the STATGRAPHICS Centurion TM
software package. Prior to his current position, George accumulated 33 years of professional experience with United Technologies and General Electric Aircraft Engines. During his career at GE, he provided statistical support, managed teams, and developed new courses and patent applications to solve a wide variety of engineering and manufacturing problems, including new process development, Reliability/Quality and Six Sigma training and project support. His individual Six Sigma andDesign for Six Sigma projects saved GE $1.5 Million.
George holds an Associate in Applied Science, a Bachelor’s Degree in Mechanical Engineering and a MS Degree in Engineering Management. He has taught undergraduate courses in Engineering Statistics and holds instructor certifications from GE and Motorola (Six Sigma). He has an Honorable Discharge from the U.S. Air Force Reserves 440th Troop Carrier Wing, Staff Sergeant.
Terry Russell
Terry Russell is Director of Management Systems for ABI Associates,Inc., a business improvement consulting practice working with domestic and international companies to improve business performance through management system and process improvement and through Six Sigma training and implementation. Clients have included companies in both product manufacturing and service sectors.
Prior to his current position, Terry accumulated 36 years of professional experience with the National Aeronautical and Space Administration and General Electric Aircraft Engines. With GE, Terry was recognized for his leadership in the development and implementation of international TQM based business improvement programs.
Terry holds a Bachelor’s Degree in Mechanical Engineering and Master’s Degrees in Mechanical Engineering and Business Administration. He holds instructor certifications from GE, Motorola (Six Sigma) and Ford (TOPS8D), and has been Leader of the Day for several Center for Quality of Management courses. He is a registered Professional Engineer in the State of Ohio and serves as Chair of the Industrial Advisory Board for the Ohio University Department of Mechanical Engineering. He has an Honorable Discharge from the U.S. Army Ordnance Corps, First Lieutenant.