Six Sigma Training Part-1Quality & Development Work

Presented By:Khondoker Shafiqul Islam UllashAM-RFL-RPL-OP Shine & Tunerfl936@rflgroupbd.com

Feel The Difference

SIX SIGMABackground of six Sigma is a set of techniques and tools for process improvement. It was introduced by engineer Bill Smith while working at Motorola in 1986. Jack Welch made it central to his business strategy at General Electric in 1995.Today; it is used in many industrial sectors.

Sigma Basics:

s (sigma) - A Greek letter In statistics - the “standard” deviation from the average/mean s– Standard Deviation, a measure of variability Assumption of Gaussian/Normal distribution Six Sigma Methodology uses to define the capability of a process As the standard deviation of your process decreases, the “sigma level” of your process increases.

Six Sigma is dentifying defects and removing them from the process of products to improve quality.

CENSO

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Normal Distribution - Gaussian Curve & Sigma Level Table:

Sigma = = Deviation ( Square root of variance )

-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7

Axis graduated in Sigma

68.27 %

95.45 %

99.73 %

99.9937 %

99.999943 %

99.9999998 %

690,000 Defects Per Million Opptunities between + / - 1between + / - 2between + / - 3between + / - 4between + / - 5

between + / - 6

=

Lesson Learned: The higher the sigma value, the better the process is capable of producing defect free results. To be in this six sigma range we must have a Quality Product 99.99998 % of all the time.

308,537 Defects Per Million Opptunities

66,807 Defects Per Million Opptunities

6,210 Defects Per Million Opptunities

233 Defects Per Million Opptunities

3.4 Defects Per Million Opptunities

DPMO

1. DPMO to Sigma Level Relationship

Defects per Million Opportunities (DPMO) – a ratio of the number of defects (flaws) in 1 million opportunities when an item can contain more than one defect. To calculate DPMO, you need to know the total number of defect opportunities.

For example: > RFL Stationery produces pencils > There are 6 defect opportunities per pencil (lead, wood, eraser, eraser clasp, color and label) > Found 4 defects every 108 units

2.SIX SIGMA METHODILOGY: Starts from DMAIC

DMAIC

D = Define: Define the problem

M = Measure: Measure the gap, listen to the process

A = Analyze: Analyze data to determine root causes

I = Improve: Improve the process – Implement the solution

C = Control: Control the process, standardize, and document – Sustain the gains

3. Fish Bone for Any Problem Analysis:

MAN Machine Material

Method Measurement

Environment

4. WHYS Analysis for Problem Sorting:

5 Whys is a SIMPLE and POWERFUL technique for uncovering the root cause of a problem when you lack data regarding why the problem is occurring. If we don’t solve problems at the level of the root cause, we risk the same problem resurfacing in the future.

PROBLEM: The vehicle will not start. Apply WHY

Why? - The battery is dead. (first why)

Why? - The alternator is not functioning. (second why)

Why? - The alternator belt has broken. (third why)

Why? - The alternator belt was well beyond its usefulservice life and not replaced. (fourth why)

Why? - The vehicle was not maintained according to therecommended service schedule. (fifth why, a root cause)

5. MISTAKE PROOFING (Poka-Yoke)

Poka-Yoke (poh ka yoke) is a mistake proofing approach to eliminating errors that was developed by the Japanese engineer Shigeo Shingo in the 1960s. “poka-yoke” derived from a Japanese word means “TO AVOID ERRORS”. Poka-yoke makes use of simple but effective tools and signals to prevent errors from occurring.

06. SINGLE MINUTE EXCHANGE OF DIE (SMED) Dr. Shigeo Shingo (1909-1990) born in Japan is known as the father of SMED.

Single-Minute Exchange of Die (SMED) is used to reduce changeover or setup time, which is the time needed between the completion of one procedure and the start of the next procedure.

6.1 "Single Minute" does not mean that all changeovers and startups should take only one minute, but that they should take less than 10 minutes (in other words, "single-digit minute").

6.2 STEPS Step 1: Separating Internal and External setup.

Step 2: Converting Internal setup to External setup.

Step 3: Streamlining all aspects of the setup operation

Note: Toyota, using this technique, reduced setup time from days to three minutes

Without Standard Work, there is no continuous improvement

Six sigma Part-2 Cont.

SMED Video:

Six sigma Part-2 Cont.