The Search for and Control of X, University of Buffalo ...
-
Upload
sixsigmacentral -
Category
Documents
-
view
236 -
download
3
Transcript of The Search for and Control of X, University of Buffalo ...
![Page 1: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/1.jpg)
6 SIGMA: THE SEARCH 6 SIGMA: THE SEARCH FOR AND CONTROL OF XFOR AND CONTROL OF X
Michael W. PiczakMichael W. PiczakDipl.T., B.Comm., MBADipl.T., B.Comm., MBA
University of BuffaloUniversity of Buffalo
May 2003May 2003
![Page 2: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/2.jpg)
WHO IS USING IT?WHO IS USING IT? MOTOROLAMOTOROLA GENERAL ELECTRICGENERAL ELECTRIC TEXAS INSTRUMENTSTEXAS INSTRUMENTS SONYSONY LOCKHEED-MARTINLOCKHEED-MARTIN RAYTHEONRAYTHEON CAMCOCAMCO BOART LONGYEARBOART LONGYEAR ALLIED SIGNALALLIED SIGNAL CRANE VALVESCRANE VALVES
![Page 3: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/3.jpg)
GOALS OF 6 SIGMAGOALS OF 6 SIGMA
Defect reductionDefect reduction Yield improvementYield improvement Improved customer satisfactionImproved customer satisfaction Higher net incomeHigher net income Cost reductionCost reduction Process improvement and optimizationProcess improvement and optimization Bottleneck relief Bottleneck relief
![Page 4: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/4.jpg)
2 ROADS TO PROFITABILITY2 ROADS TO PROFITABILITY
![Page 5: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/5.jpg)
FIXING BELIEFFIXING BELIEF
Method of tenacityMethod of tenacity Method of authorityMethod of authority Method of reasoningMethod of reasoning Method of scienceMethod of science
![Page 6: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/6.jpg)
6 SIGMA: IN GOLFING PERSPECTIVE6 SIGMA: IN GOLFING PERSPECTIVE
6 sigma quality levels amount to 3.4 defects 6 sigma quality levels amount to 3.4 defects per million or 99.999966% good.per million or 99.999966% good.
2 sigma = missing 6 putts per round2 sigma = missing 6 putts per round 3 sigma = missing 1 putt per round3 sigma = missing 1 putt per round 4 sigma = missing 1 putt every 9 rounds4 sigma = missing 1 putt every 9 rounds 5 sigma = missing 1 putt every 2.33 years5 sigma = missing 1 putt every 2.33 years 6 sigma = missing 1 putt every 163 years6 sigma = missing 1 putt every 163 years* based on 100 rounds per year* based on 100 rounds per year
![Page 7: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/7.jpg)
PROBLEM SOLVING PROBLEM SOLVING TOOLS AND MODELSTOOLS AND MODELS
MICHAEL W. PICZAKMICHAEL W. PICZAKDIPL.T., B.COMM., MBADIPL.T., B.COMM., MBA
MARCH 2002MARCH 2002
![Page 8: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/8.jpg)
Traditional Problem Traditional Problem Solving Models…Solving Models…
![Page 9: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/9.jpg)
Piczak, Piczak, 19951995
![Page 10: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/10.jpg)
NARROW VS. BROAD NARROW VS. BROAD CONCEPTUALIZATIONCONCEPTUALIZATION
AS QUALITY PROGRAM AS QUALITY PROGRAM
OROR
STAND ALONE OPERATIONS STAND ALONE OPERATIONS RESEARCH METHODOLOGYRESEARCH METHODOLOGY
![Page 11: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/11.jpg)
AS QUALITY PROGRAMAS QUALITY PROGRAM
Improvement Process
Basic Components
Quality Initiatives
Enabling Initiatives and Tools
Improvement ToolsQuality Measurement
1 . D e fine P roduc ts and S e rv ices2 . Iden tify C us tom er R equ irem en ts3 . C om pare P roduc t w ith R equ irem en ts4 . D esc ribe the P rocess5 . Im prove the P rocess6 . M easure Q ua lity and P roduc tiv ity
1 . S e lf D irec ted W ork T eam s2 . S ho rt-cyc le M anu fac tu ring3 . D es ign fo r M anu fac tu re4 . B enchm ark ing5 . S ta tis tica l P rocess C on tro l6 . S upp lie r Q ua lifica tion
1 . O ld M e trics - p rocess m ean ( ) ands tandard dev ia tion ( )2 . C apab ility Index C p , C pk3 . N ew M e trics - de fec ts pe r un it (dpu ), de fec ts pe r m illion un its (dpm u)4 . C os t o f Q ua lity S tud ies
1 . Q ua lity F unc tion D ep loym en t2 . F low cha rts3 . P are to C harts4 . H is tog ram s5 . C ause-and-E ffec t D iag ram s6 . E xperim en ta l D es ign7 . G uage R & R
![Page 12: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/12.jpg)
QUALITY INITIATIVESIMPROVEMENT
PROCESS
IMPROVEMENT TOOLSQUALITY
MEASUREMENT
6 SIGM A
Motorola’s 6 Sigma ProgramMotorola’s 6 Sigma Program
![Page 13: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/13.jpg)
AS STAND ALONE OPERATIONS AS STAND ALONE OPERATIONS RESEARCH METHODOLOGYRESEARCH METHODOLOGY
![Page 14: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/14.jpg)
WHO IS THE ENEMY?WHO IS THE ENEMY?
VARIATIONVARIATION
![Page 15: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/15.jpg)
WHAT ARE WE REACHING FOR?WHAT ARE WE REACHING FOR?
![Page 16: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/16.jpg)
PRIMARY SOURCES OF VARIATIONPRIMARY SOURCES OF VARIATION
Inadequate design marginInadequate design margin Unstable parts and materialUnstable parts and material Insufficient process capabilityInsufficient process capability
![Page 17: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/17.jpg)
WHERE TO FOCUS?WHERE TO FOCUS?
For each product or process critical to quality For each product or process critical to quality (CTQ):(CTQ):
MeasureMeasure AnalyzeAnalyze ImproveImprove ControlControl
![Page 18: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/18.jpg)
GENESIS OF 6 SIGMAGENESIS OF 6 SIGMA
DefineRequirements and
Set Targets
Measure ResultsAgainst Targets
AnalyzeDifferences
Between Targetsand Results
Recommend andImplement
Improvements
![Page 19: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/19.jpg)
ELEMENT 1ELEMENT 1
![Page 20: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/20.jpg)
PORTER’S 5 FORCES MODELPORTER’S 5 FORCES MODEL
![Page 21: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/21.jpg)
PEST MODELPEST MODEL
![Page 22: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/22.jpg)
VOICE OF THE CUSTOMERVOICE OF THE CUSTOMER
2 Brands of customers2 Brands of customersinternalinternalexternalexternal
![Page 23: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/23.jpg)
Voice of the Voice of the customercustomer
![Page 24: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/24.jpg)
DESCRIBE THE PROCESSDESCRIBE THE PROCESS
M1 R N
R efe r to phys ic iano rder OR respond to
ca ll be ll re : P R N
$2033 .05 A 121G et na rco tics keys ifnecessary and take
cart to room
$4062 .45 A 122W ake res iden t &
repos ition by e leva tinghead o f bed , ad jus ting
pos ition (e .g . fla t onback)
$10157 .95 A 123
P our m ed ica tion , se lec ttab le ts o r c rush in to
app lesauce & g ive tores iden t
$2033 .05 A 124 Low er head o f bed &repos ition com fo rtab ly
$10157 .95 A 125 D ocum ent rec iep t o r
re fusa l o f m ed ica tion inN urs ing N o tes , M A R SS hee t & R eport S hee t
$2033 .05 A 126
IdentifiedR x N eed
O bta inedK eys/C hart
P reparedR es ident
A dm in is teredM edication
R e-pos itionedR es ident
I1M onitored
R es ident
C1 P rofess iona l G u ide lines C2 H osp ita l P o lic ies & P rocedures
M2 R P N
O 1R esident C areP rov ided
O 2A dm in is teredM edication
![Page 25: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/25.jpg)
IMPROVING THE PROCESSIMPROVING THE PROCESS
EliminationElimination SimplificationSimplification CombinationCombination ReuseReuse Parallel processingParallel processing SubcontractingSubcontracting
![Page 26: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/26.jpg)
CRITICAL EXAMINATIONCRITICAL EXAMINATION
![Page 27: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/27.jpg)
NO NEW PROBLEMS PLEASENO NEW PROBLEMS PLEASE
Poka Yoke techniquesPoka Yoke techniques• guide pinsguide pins
• templatestemplates
• limit switcheslimit switches
• limited computer screen fieldslimited computer screen fields
• checklistschecklists
• interconnectsinterconnects
![Page 28: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/28.jpg)
GETTING BETTER?GETTING BETTER?
The need to measure in quantitative The need to measure in quantitative terms importantterms important
ISO/QS9000 demands it in terms of ISO/QS9000 demands it in terms of quality and effectivenessquality and effectiveness
• customer satisfactioncustomer satisfaction• quality levels (# non-conformances, dpu, dpmo)quality levels (# non-conformances, dpu, dpmo)• cycle timescycle times• die change timesdie change times
![Page 29: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/29.jpg)
ELEMENT 2: MEASUREMENTELEMENT 2: MEASUREMENT
Quality Measurement
1 . O ld M etrics - p rocess m ean ( ) ands tandard dev ia tion ( )2 . C apab ility Index C p , C pk3 . N ew M e trics - de fec ts pe r un it (dpu ), de fec ts pe r m illion un its (dpm u)4 . C os t o f Q ua lity S tud ies
![Page 30: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/30.jpg)
OLD METRICSOLD METRICS
Measures of central tendency or Measures of central tendency or typicality (mean, median, mode)typicality (mean, median, mode)
Measures of dispersion (range, variance, Measures of dispersion (range, variance, standard deviation)standard deviation)
![Page 31: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/31.jpg)
THE NORMAL DISTRIBUTIONTHE NORMAL DISTRIBUTION
![Page 32: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/32.jpg)
A KEY FORMULAA KEY FORMULA
![Page 33: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/33.jpg)
NORMAL CURVE CHARACTERISTICSNORMAL CURVE CHARACTERISTICS
ContinuousContinuous SymmetricalSymmetrical Tails asymptotic to zeroTails asymptotic to zero Bell shapedBell shaped Mean = median = modeMean = median = mode Total area under curve = 1Total area under curve = 1
![Page 34: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/34.jpg)
VISUALIZING VARIATIONVISUALIZING VARIATION
![Page 35: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/35.jpg)
![Page 36: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/36.jpg)
PROCESS CAPABILITYPROCESS CAPABILITY
![Page 37: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/37.jpg)
PROCESS CAPABILITY IIPROCESS CAPABILITY II
![Page 38: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/38.jpg)
CpkCpk
![Page 39: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/39.jpg)
CAPABILITY ST & LTCAPABILITY ST & LT
![Page 40: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/40.jpg)
Cp LONG TERM (LT)Cp LONG TERM (LT)
![Page 41: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/41.jpg)
ST to LTST to LT
![Page 42: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/42.jpg)
NEW METRICSNEW METRICS
dpudpu dmpodmpo
A CAVEAT A CAVEAT ABOUT DPMOABOUT DPMO
![Page 43: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/43.jpg)
JURAN’S COSTS OF QUALITY JURAN’S COSTS OF QUALITY
Prevention Appraisal
D iscre tionary C os ts
InternalNon-conform ance
ExternalNon-conform ance
C onsequentia l C os ts
C osts O f Q ua lity
![Page 44: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/44.jpg)
ELEMENT 3: QUALITY INITIATIVESELEMENT 3: QUALITY INITIATIVES
Quality Initiatives
1 . S e lf D irec ted W ork T eam s2 . S ho rt-cyc le M anu fac tu ring3 . D es ign fo r M anu fac tu re4 . B enchm ark ing5 . S ta tis tica l P rocess C on tro l6 . S upp lie r Q ua lifica tion
![Page 45: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/45.jpg)
SDWTsSDWTs
From Quality Progress, From Quality Progress, October 1996October 1996
![Page 46: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/46.jpg)
LITERATURE IDENTIFIED BENEFITSLITERATURE IDENTIFIED BENEFITS
Productivity Productivity 15% -250% 15% -250%
All employees can perform all tasksAll employees can perform all tasks
Costs Costs 30% 30%
Cycle time Cycle time 50%-90% 50%-90%
Inventory Inventory 66% 66%
Rework due to engineering flaws Rework due to engineering flaws 50% 50%
![Page 47: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/47.jpg)
BENEFITS CONT’DBENEFITS CONT’D
Late jobs Late jobs 1000% 1000%
Quality Quality
Recurring defective product problems Recurring defective product problems 10% 10%
Return on investment/sales Return on investment/sales
![Page 48: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/48.jpg)
BENEFITS CONT’DBENEFITS CONT’D
Sales Sales 830% 830%
Operating statistics improved by 25-40%Operating statistics improved by 25-40%
Accounts receivable Accounts receivable from 66 days to 51 from 66 days to 51 daysdays
Corporate overhead Corporate overhead from $100M to from $100M to $24M$24M
Accidents Accidents 72% 72%
![Page 49: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/49.jpg)
SHORT CYCLE MFG.SHORT CYCLE MFG.
SMEDSMEDautomated & computerized inspectionautomated & computerized inspection X and moving range control chartsX and moving range control charts automated systems automated systems
(MAPs/CAD/CAM/flexible mfg., etc.)(MAPs/CAD/CAM/flexible mfg., etc.) flexible, self directed work forceflexible, self directed work force
![Page 50: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/50.jpg)
DFMDFM
group technologygroup technology accessibility of different parts & areasaccessibility of different parts & areas ease of workpiece handlingease of workpiece handling ergonomic principlesergonomic principles safety requirementssafety requirements appearanceappearance QFDQFD
![Page 51: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/51.jpg)
BENCHMARKINGBENCHMARKING
more than just organized tourismmore than just organized tourism more than just a nice walk over at a more than just a nice walk over at a
friend’s plantfriend’s plant not industrial espionagenot industrial espionage not a one way channel of communicationnot a one way channel of communication inside and outside of your industryinside and outside of your industry
![Page 52: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/52.jpg)
THE ALCOA SEQUENCETHE ALCOA SEQUENCE
![Page 53: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/53.jpg)
SPCSPC
using numbers to describe absence or using numbers to describe absence or presence of a phenomenonpresence of a phenomenon
systematic gathering of datasystematic gathering of data using a collection of analytics that using a collection of analytics that
promote common understanding and promote common understanding and profound knowledge (Deming)profound knowledge (Deming)
emphasis is on measurementemphasis is on measurement
![Page 54: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/54.jpg)
STATISTICSSTATISTICS
CollectingCollecting OrganizingOrganizing SummarizingSummarizing AnalyzingAnalyzing PresentingPresenting
![Page 55: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/55.jpg)
THE ANALYST’S DUTYTHE ANALYST’S DUTY
start with a regularity, uniformity or curiositystart with a regularity, uniformity or curiosity identify all previously significant predictors of identify all previously significant predictors of
phemon in questionphemon in question theorize as to why independent variables (X’s) theorize as to why independent variables (X’s)
should be predictive of dependent variables (Y)should be predictive of dependent variables (Y) tease out the key X’s that impact Y and control tease out the key X’s that impact Y and control
samesame
![Page 56: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/56.jpg)
ELEMENT 4: IMPROVEMENT TOOLSELEMENT 4: IMPROVEMENT TOOLS
![Page 57: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/57.jpg)
Voice of the Voice of the customercustomer
![Page 58: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/58.jpg)
Flowchart For Classic Problem SolvingFlowchart For Classic Problem Solving
Don’t Mess With It!
YES NO
YES
YOU IDIOT!
NO
Will it Blow UpIn Your Hands?
NO
Look The Other Way
Anyone ElseKnows? You’re F*@~#D!
YESYES
NO
Hide ItCan You Blame Someone Else?
NO
NO PROBLEM!
Yes
Is It Working?
Did You Mess With It?
![Page 59: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/59.jpg)
PARETO ANALYSISPARETO ANALYSIS
![Page 60: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/60.jpg)
HISTOGRAMSHISTOGRAMS
![Page 61: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/61.jpg)
CAUSE & EFFECT DIAGRAMS & CARDSCAUSE & EFFECT DIAGRAMS & CARDS
![Page 62: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/62.jpg)
SYSTEMATIC CAUSES OF VARIATIONSYSTEMATIC CAUSES OF VARIATION
Lack of preventative maintenanceLack of preventative maintenance Worn toolsWorn tools Operator performanceOperator performance Environmental changesEnvironmental changes Sorting practicesSorting practices MaterialsMaterials Measurement SystemMeasurement System
![Page 63: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/63.jpg)
SELECTION OF RESPONSE VARIABLE (Y)
CHOICE OF FACTORS (Xi’s), LEVELS, RANGES
RECOGNITION OF & STATEMENT OF PROBLEM
CHOICE OF EXPERIMENTAL DESIGN
PERFORMING EXPERIMENT
STATISTICAL ANALYSIS OF DATA
CONCLUSIONS, RECOMMENDATIONS, NEXT STEPS
![Page 64: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/64.jpg)
NASA DATA & REGRESSION LINENASA DATA & REGRESSION LINE
'O' RING EROSION x TEMPERATURE
-20-10
0102030405060
0 25 50 75 100
Launch Temperature (F.)
Ero
sio
n D
epth
(t
ho
usa
nd
ths)
![Page 65: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/65.jpg)
REGRESSION ANALYSISREGRESSION ANALYSIS
![Page 66: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/66.jpg)
ALWAYS LOOK AT THE DATA FIRSTALWAYS LOOK AT THE DATA FIRST
![Page 67: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/67.jpg)
AS STAND ALONE OPERATIONS AS STAND ALONE OPERATIONS RESEARCH METHODOLOGYRESEARCH METHODOLOGY
![Page 68: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/68.jpg)
THE HUNT FOR XTHE HUNT FOR X
![Page 69: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/69.jpg)
6 SIGMA: OLD WINE OUT 6 SIGMA: OLD WINE OUT OF NEW BOTTLES?OF NEW BOTTLES?
![Page 70: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/70.jpg)
RANKING BY USE OF PARETO PRIORITY INDEX (PPI)
PROJECT SAVINGS PROBABILITY COST TIME PPI(K$) (K$) (YEARS)
A 100 0.7 10 2 3.5
B 50 0.7 2 1 17.5
C 30 0.8 1.6 0.25 60
D 10 0.9 0.5 0.5 36
E 1.5 0.6 1 0.1 9
DUPONT’S PPIDUPONT’S PPI
![Page 71: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/71.jpg)
3 KINDS OF STATISTICS3 KINDS OF STATISTICS
Descriptive Descriptive InferentialInferential PredictivePredictive
![Page 72: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/72.jpg)
![Page 73: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/73.jpg)
GE’s MAICGE’s MAIC
![Page 74: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/74.jpg)
![Page 75: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/75.jpg)
JURAN’s 6 SIGMA PROGRAMJURAN’s 6 SIGMA PROGRAM
![Page 76: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/76.jpg)
Xs, Ys, and Zs of DOEXs, Ys, and Zs of DOE
![Page 77: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/77.jpg)
SELECTION OF RESPONSE VARIABLE (Y)
CHOICE OF FACTORS (Xi’s), LEVELS, RANGES
RECOGNITION OF & STATEMENT OF PROBLEM
CHOICE OF EXPERIMENTAL DESIGN
PERFORMING EXPERIMENT
STATISTICAL ANALYSIS OF DATA
CONCLUSIONS, RECOMMENDATIONS, NEXT STEPSCLASSIC DOECLASSIC DOE
![Page 78: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/78.jpg)
![Page 79: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/79.jpg)
![Page 80: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/80.jpg)
6 SIGMA TRAINING TERMINAL 6 SIGMA TRAINING TERMINAL PERFORMANCE OBJECTIVESPERFORMANCE OBJECTIVES
As a result of taking this program, the participant As a result of taking this program, the participant will be able to:will be able to:
Appreciate the scope of 6 Sigma practices in Appreciate the scope of 6 Sigma practices in context of other company initiativescontext of other company initiatives
Apply a variety of tools to solve problemsApply a variety of tools to solve problems
![Page 81: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/81.jpg)
T.P.O.s CONTINUED...T.P.O.s CONTINUED...
Participate as a contributing member of Participate as a contributing member of a continuous improvement or problem a continuous improvement or problem solving teamsolving team
Use Minitab as a data analysis toolUse Minitab as a data analysis tool
![Page 82: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/82.jpg)
PEDAGOGICAL APPROACHPEDAGOGICAL APPROACH
LectureLecture Discussion, debate and argumentDiscussion, debate and argument VideosVideos Hands-on exercises using general and Hands-on exercises using general and
company specific examplescompany specific examples
![Page 83: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/83.jpg)
A BASIC RESEARCH PARADIGMA BASIC RESEARCH PARADIGM
Select the operation to be analyzedSelect the operation to be analyzed Explicate key variables a prioriExplicate key variables a priori Gather data on key X’s and Y’sGather data on key X’s and Y’s Enter data and edit sameEnter data and edit same Verify data integrity via Look, Counts, Describe, Verify data integrity via Look, Counts, Describe,
Scatter DiagramScatter Diagram Run DescriptivesRun Descriptives Generate other graphs & charts of dataGenerate other graphs & charts of data GR&Rs, regressions, ANOVAs, DOEs, GR&Rs, regressions, ANOVAs, DOEs,
![Page 84: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/84.jpg)
THE JOURNEYTHE JOURNEY
Most companies presently at 3-4 sigmaMost companies presently at 3-4 sigma The move is toward 6 sigma (Cp = 2)The move is toward 6 sigma (Cp = 2) Literature has references to 12 sigma Literature has references to 12 sigma
(Cp = ?)(Cp = ?)Tinnerman-Pallnut is at 50 ppb on Tinnerman-Pallnut is at 50 ppb on
selected product linesselected product lines
![Page 85: The Search for and Control of X, University of Buffalo ...](https://reader033.fdocuments.in/reader033/viewer/2022060118/558bd0a4d8b42abc448b4613/html5/thumbnails/85.jpg)
6 SIGMA: THE SEARCH 6 SIGMA: THE SEARCH FOR AND CONTROL OF XFOR AND CONTROL OF X
Michael W. PiczakMichael W. PiczakDipl.T., B.Comm., MBADipl.T., B.Comm., MBA