Six Sigma By Mhussain

European Technology Development Ltd.

Introduction to Six Sigma

Presented By:Muhammad HussainCountry [email protected]

mailto:[email protected]


Six Sigma is.....

A performance goal, representing 3.4 defects for every million opportunities to make one.

A series of tools and methods used to improve or design products, processes, and/or services.

A statistical measure indicating the number of standard deviations within customer expectations.

A disciplined, fact-based approach to managing a business and its processes.

A means to promote greater awareness of customer needs, performance measurement, and business improvement.


A scientific and practical method to achieve

improvements in a company

Scientific:

• Structured approach.

• Assuming quantitative data.

Practical:

• Emphasis on financial result.

• Start with the voice of the customer.

“Show me

the data”

”Show me

the money”

Six Sigma


Knowledge

Management

The Six Sigma Initiative integrates these efforts


Six Sigma

Methods Production

DesignService

Purchase

HRM

Administration

QualityDepart.

Management

Health

IT

Where can Six Sigma be applied?


Input InspectOperation

OKOutput

Quality =

Customer satisfaction

= Profit and Growth

1_04_01_004

Rework

NOT

OK

ScrapHidden

Factory


„Six Sigma‟ companies

Companies who have successfully adopted „Six Sigma‟ strategies include:


Statistical background

Target = m

Some Key measure


+/- 3s


Target = m

„Control‟ limits


+/- 3sLSL USL


Required Tolerance

Target = m


+/- 3s

+/- 6s

LSL USL


Tolerance

Target = m

Six-Sigma


+/- 3s

+/- 6s

LSL USL

ppm1350

ppm1350


Tolerance

Target = m


+/- 3s

+/- 6s

LSL USL

ppm0.001

ppm1350

ppm1350

ppm0.001


Tolerance

Target = m


Specification

Process Width

Design Width

Target

+ 6s- 6s

s s s s s s

Specification

6 “sigmas” fit in here


Sigma % Good % Bad DPMO(Defect Per Million Opportunity)

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


The Six Sigma Methodology


Define

Measure

Analyze

Improve

Control

Continuously

repeat and

improve!

No complacency

with success!

The Six Sigma Methodology

Process

Characterization

Process

Optimization

Opportunity

Identification

The 5 phases of the Six Sigma Methodology


Defect / Variation Reduction Roadmap

Define Measure Analyze Improve Control

A. Identify Project

VOC’s & KPIV’s

Deliverables:

1) Identify Customer(s)

2) Collect VOC

3) Identify the Key

Process Input

Variables (KPIV’s)

that effect the VOC’s.

B. Develop

Team Charter

Deliverables:

1) Develop The

Business Case

2) Develop The

Problem and Goal

Statements

3) Determine Project

Scope

4) Select Team &

Define Roles

5) Set Project

Milestones

C. Define

Process Map

Deliverables:

1) High Level Process

Map Connecting the

Customer to the

Process

2) Summary of Define

Phase

Tools:

Process Mapping




1. Select KPOV

Characteristics

Deliverable:

Identify Measurable Key

Process Output Variable

(KPOV) that will be

Improved

Tools:

Quality Function

Deployment (QFD)

Process Mapping

Cause & Effect Diagram

FMEA

Discrete vs. Contin. Data

2. Define Perfor-

mance Standards

Deliverable:

Determine and

Confirm Specification

Limits for your Y.

3. Measurement

System Evaluation

Deliverables:

1)Measurement

System Adequate to

Measure Y

2)Summary of Measure

Phase.

Tools:

Continuous Gage

R&R

Test / Retest

Attribute Gage R&R




5. Define Perfor-

mance Objectives

Deliverable:

Statistically Define the

Goal of the Project

Tools:

Benchmarking

4. Establish

Process Capability

Deliverable:

Baseline Current

Process

Tools:

Basic statistics

Graphical Analysis

Sampling

Continuous Zst, Zlt

Normality

Discrete Zst, Zlt

6. Identify Variation

Sources

Deliverable:

List of Statistically

Significant X’s,

Chosen Based on

Analysis of Historical

Data

Tools:

Process Analysis

Graphical Analysis

Hypothesis Testing

Regression Analysis




8. Discover Variable

Relationships

Deliverables:

1) Establish Transfer

Function Between Y

and Vital Few X’s.

2) Determine Optimal

Setting for the Vital

Few X’s.

3) Perform Confirmation

Runs.

Tools:

DOE, Factorial

Designs

7. Screen Potential

Causes

Deliverable:

Determine the Vital

Few X’s That Are

Causing Changes

in Y.

Tools:

Screening Design of

Experiments (DOE)

9. Establish Operating

Tolerances

Deliverable:

Specify Tolerances on

the Vital Few X’s.

Tools:

Simulation




11. Determine

Process Capability

Deliverables:

1) Determine Post-

Improvement

Capability and

Performance

2) Confirm that the

Improvement Goal

has been realized

Tools:

See Step 4

10. Define and Validate

Measurem. System

Deliverable:

Measurement System

is Adequate to

Measure X’s in the

Actual Application

Tools:

See Step 3

12. Implement

Process Control

Deliverable:

Develop and

Implement Process

Control Plan

Tools:

FMEA

Poka-Yoke

5-S

Training / Certification

Stat. Process Control

Std. Work Processes


Example - Design of Experiments

What can it do for you?

Minimumcost

Maximumoutput


Example - SPC (Statistical Process Control)

- reduces variability and keeps the process stable

Disturbed process

Natural processTemporary

upsets

Natural boundary

Natural boundary


Results of SPC

An improvement in the process

Reduction in variation

Better control over process

Provides practical experience of collecting useful information for analysis

Hopefully some enthusiasm for measurement!


Key Quality Characteristics “CTQs”

How will you measure them?

How often?

Who will measure?

Is the outcome critical or important to results?


-Brainstorming

-Exploratory data analysis

6. Identify factorsMaterialMachineMan

Method Measure-ment

MotherNature

Amount of

added water

Roasting

machines

Batch

size

Reliability

of Quadra Beam

Weather

conditions

Moisture%

Discovery of causes


Benefits

Better monitoring of processes

Better involvement of people

Staff morale is raised

Throughput is increased

Profits go up


Thank You very much for your attention.

Questions?

30

Six Sigma By Mhussain

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