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Chapter 13
Six-Sigma Management and
Lean Tools
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsChapter 13
What is Six-Sigma?Organizing Lean Six-SigmaDMAIC OverviewDMAIC PhasesThe Taguchi Design of ExperimentsDesign for Six-SigmaLean Six-Sigma from a Contingency Perspective
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsWhat is Six-Sigma?
Sigma () is a greek letter used to designate a standard deviation (SD) in statistics
Six refers to the number of SD’s from the specialized limit to the mean.
Six-Sigma: about 0.5% of products will not meet specification
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsWhat is Six-Sigma?
* ppm = Parts Per Million
Sigma Level Long-term ppm* defects
1 691,462
2 308,538
3 66,807
4 6,210
5 233
6 3.4
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsWhat is Six-Sigma?
Six-Sigma effectiveness
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsOrganizing Six-Sigma
The key playersChampion. Work with black belts to identify possible projectsMaster Black Belts. Work with and train new black beltsBlack Belts. Committed full time to completing cost-reduction projectsGreen Belts. Trained in basic quality tools
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsOrganizing Six-Sigma
In a company with 100 employees there might be: One black beltSixty green beltsSome companies have yellow belts, employees familiar with improvement processes
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsOrganizing Six-Sigma
Lean-Six SigmaPull productionValue-stream map
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsDMAIC Overview
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsDMAIC Phases
Define- projects are identified and selected
Four Phases:1. Developing the business case
2. Project evaluation
3. Pareto analysis
4. Project definition
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsDMAIC Phases
Define Developing the Business Case:
1. Identifying a group of possible projects
2. Writing the business case
3. Stratifying the business case into problem statement and objective statements
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsDMAIC Phases
Define RUMBA is used to check the efficacy
of the business case 1. Realistic
2. Understandable
3. Measurable
4. Believable
5. Actionable
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Project Risk and Return Matrix
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsDMAIC Phases
Measure Two major steps:
1. Selecting process outcomes
2. Verifying measurements
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsDMAIC Phases
Measure Two major steps:
1. Select process outcomes Tools used:
Process map XY matrix FMEA Gauge R&R Capability Assessment.
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsDMAIC Phases
Process Map
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsDMAIC Phases
XY Matrix
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsDMAIC Phases
XY Matrix for Example 13-3
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsDMAIC Phases
Solution for Example 13-3
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsDMAIC Phases
Measure Two major steps:
2. Verifying measurements Tools Used:
Use gauges, calipers and other tools.
Management System Analysis (MSA) is used to determine if measurements are consistent
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsDMAIC Phases
Measure Two major steps:
2. Verifying measurements Gauge R&R
Most commonly used MSA Determine the accuracy and
precision of your measurements
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsDMAIC Phases
Gauge R&R in Excel
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsDMAIC Phases
Analyze Three major steps:
1. Define your performance objectives
2. Identify independent variables (X’s)
3. Analyze sources of variability
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsDMAIC Phases
Analyze Three major steps:
1. Define your performance objectives Capability Analysis Identify the independent variables
where data will be gathered Process maps, XY matrices
brainstorming and FMEA’s are the tools used
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsDMAIC Phases
Capability Analysis
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsDMAIC Phases
Analyze Three major steps:
Analyze sources of variability Use visual and statistical tools to better
understand the relationships between dependent and independent variables
Include histograms, box plots, scatter plots, regression analysis, and hypothesis tests
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsDMAIC Phases
Improve Off-line experimentation
ANOVA Taguchi Method
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsDMAIC Phases
Control Manage the improved processes using
control charts and implementing control plans
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Strategic Quality PlanningSix-Sigma Management and Lean Tools The Taguchi Method
Design of Experiment (DOE) Robust Design Concept Design Parameter Design Tolerance Design
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Strategic Quality PlanningSix-Sigma Management and Lean Tools The Taguchi Method
Design of Experiment (DOE) Robust design - designed so that they are
inherently defect free Concept Design - examining competing
technologies Parameter Design- selection of control factors
and the determination of optimal levels for each of the factors
Tolerance Design- developing specification limits
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Strategic Quality PlanningSix-Sigma Management and Lean Tools The Taguchi Method
The Taguchi Method provides:
1. A basis for determining the functional relationship between controllable design factors and the outcomes of a process
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Strategic Quality PlanningSix-Sigma Management and Lean Tools The Taguchi Method
The Taguchi Method provides:
2. A method for adjusting the mean of a process by optimizing controllable variables
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Strategic Quality PlanningSix-Sigma Management and Lean Tools The Taguchi Method
The Taguchi Method provides:
3. A procedure for examining the relationship between random noise … and product or service variability
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Strategic Quality PlanningSix-Sigma Management and Lean Tools The Taguchi Method
Classic QC- Step Function
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Strategic Quality PlanningSix-Sigma Management and Lean Tools The Taguchi Method
Taguchi Quadratic Loss Function
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Strategic Quality PlanningSix-Sigma Management and Lean Tools The Taguchi Method
The Taguchi Process
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Strategic Quality PlanningSix-Sigma Management and Lean Tools Design for Six-Sigma (DFSS)
Used in designing new products with high performance Instead of DMAIC
1. DMADV
2. IDOV
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Strategic Quality PlanningSix-Sigma Management and Lean Tools Design for Six-Sigma (DFSS)
Used in designing new products with high performance DMADV
1. Design
2. Measure
3. Analyze
4. Design
5. Verify
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Strategic Quality PlanningSix-Sigma Management and Lean Tools Design for Six-Sigma (DFSS)
Used in designing new products with high performance IDOV
1. Identify
2. Design
3. Optimize
4. Verify
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsSix-Sigma from a Contingency Perspective
Reasons for Six-Sigma failure:1. Lack of leadership by
champions
2. Misunderstood roles and responsibilities
3. Lack of appropriate culture for improvement
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Strategic Quality PlanningSix-Sigma Management and Lean Tools failure Six-Sigma from a Contingency Perspective
Reasons for Six-Sigma failure:4. Resistance to change and the
Six-Sigma structure
5. Faulty strategies for deployment
6. Lack of data
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Strategic Quality PlanningSix-Sigma Management and Lean ToolsSummary
The process for Six-Sigma is define, measure, analyze, improve and control
Keys to Six-Sigma success are skilled management, leadership and long-term commitment
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