Villads Haar Jakobsen, WTG Platform and Diagnostics

A brief introduction to Six Sigma - Data driven problem solving

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June 27, 2012

Agenda

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• What is it actually

• Purpose of Six Sigma

• Example of a Six Sigma project organisation

• What about all these belts?

• Different Six Sigma methodologies

• DMAIC

• DFSS

• Where could Six Sigma be used at DONG Renewables

What is it actually?

Six Sigma: A method A well defined process and tool kit used for:

Product & service improvements Design of products and services

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Six Sigma: A Metric The "six Sigma level" of a process can be used to express its capability

How well it performs with respect to customer requirements Defects per million opprotunities

Six Sigma: Symbol, value, benchmark or goal Greek letter which defines standard deviation in statistics Standard deviation is a measure for spread/variation

The average distance of the data points to the mean

Purpose of Six Sigma

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To reduce variation To work with continous improvements To reduce cost of poor quality / reliability To make decisions based on statistical basis

Release the full potential

Example of a Six Sigma project organization

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What about all these belts??

White belt For managers What can we gain from six sigma projcts How do we understand the language of six sigma

Yellow belt Know the stages in DMAIC Understanding of the 7 basic tools and some statistics

Green belt Know about the basic statistical tools used in six sigma Six Sigma project manager

Black belt High level of statistical tools used in six sigma Six sigma project manager Coaching green belts

Master black belt Extensive experience from many six sigma projects

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Different Six Sigma methodologies

Six Sigma

DMAIC DFSS

DMADV

Design MethodologyImprovement methodology

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DMAIC Process flow and objectives

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DMAIC Examples of tools

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• Problem statement• Process map• Fishone diagram• Voice of the customer• CTQ's

• Pareto• Histogram• Fishbone• SIPOC• C&E matrix• Data collection

plan• Data quality (MSA)• Capability analysis• Process stability

(control charts)

• FMEA• Histograms,

Boxplots, Multi-vari charts, main effects plots, interaction plots, etc.

• Hypothesis tests• T-tests• ANOVA

• Regression analysis

• FMEA• Pugh matrix• Project

inplementation• DoE• EVolutionary

Operations (EVOP)• Process mapping• Capability analysis

• Audit plan• SPC• Hypothesis testing

What is the project

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DDefine

Problem statement Define the goals What is the cost of the problem Who are the stakeholders What are the customer requirements

Ojective statement

How does the existing process work?

How is the process and the flow

Project charter

Baseline and capability MMeasure

What is the current performance?

Understand the process behaviour Which factors influence the output Verify the mesurement system Data collection Look for patterns Calculate the capability

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Potential root causes AAnalyze

What are the key root causes?

Identify sources of variation Determine the critical process

parameters Develop and confirm theories

using data

What possible solutions have been identified?

Models with the highest explanatory power

y = f (x1, x2, x3 . . . xn)Critical Xs

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Developement of solutions and implement

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IImprove

Implement the solution

Risk management Contingency plan

Make a pilot project and compare with initial data Implement the solution Calculate performance (capability)

Evaluate the solutions and optimize choosen solution

Which solution provides the best output for the customer Cost benefit analysis

Perhaps it is necessary with additional experiments Optmize chosen solution

Time

Quality/reliability

Cost

Sustainable solution

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CControl

How do we keep the benefits of the new solution

Optimize and refine solution Make a follow up plan for the implemented solution Monitor and control

DFSS

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• Kano/survey• Project management

tools• Project selection• Benchmarking• SIPOC• C&E matrix• CTQ matrix

• Brainstorming• FMEA screening• DoE• QFD• Benchmarking• Process map

• FMEA • Reliability

• Robustness• Risk analysis• Pareto analysis• Gap analysis

• Robust design• Taguchi

• DoE• Specification design• Work design• Machine design• Engineering design

• Reliability test• FMEA• Simulation• SPC• Control plan

Charter CTQ's Concept and design selection

Detailed product design Prototype

Examples of areas where Six Sigma could be used at DONG

Developement/implementation phase

• Choose optimum supplier / component

• Evaluation of reliability

• Quality inspection

Within warranty phase

• Concerns about the life of components

• Compare performance

Out of warranty phase

• Optimize settings

• RCA

• Improve processes

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• When working with experiments (DoE)

• RCA

• Improve processes

• Life tests – Robustness and Reliability

• RCA

• Improve processes

Questions?

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Back up – Bathtub curve and the Weibull distribution

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Normal life phase

Constant failure rate

Wear out phase

Increasing failure rate

Infant mortality

Decreasing failure rate

β < 1 β = 1 β > 3

β > 5

λ

TimeUp to "5" yrs ≈ 20 ?

RCA – Analysis of life data

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