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  • LEAN/SIX SIGMA

    SIX SIGMA ? SIX SIGMA TRAINING/WORKSHOP 14 JUNE 2014

    Facilitators

    Sirichai Sukhumanant

    Preecha Powanusorn

    Ruttawut Roschuen

    Jaruwan Liwsrisakul

  • Synergy

    NPD

    Cycle Time

    Warranty

    waste

    Speed Reliability Productivity

    !

  • Delighters

    Must Be

    Delight

    Neutral

    Dissatisfaction

    Fulfilled Absent

    Resigned to Reality

    Taken for

    Granted

  • ?

  • Six Sigma

    ()

    DFSS

    ()

    Features

    Deficiencies

    0

    (Client) (Customer)

    Grade

    Indifference

  • 1.

    2.

    2.1 Breakthrough

    2.2 Kaizen

    3. Six SIGMA Breakthrough - Define

    - Measure

    - Analyze

    - Improve

    - Control

  • FMEA MEASURE

    2

    INNOVATE &

    IMPROVE

    CONTROL

    MEASURE

    ANALYZE

    5 1

    2

    3

    4

    DEFINE

  • (VARIATION)

    (Variation) 2

    Common Causes (

    ) (Chronic)

    Special Causes

    (Sporadic)

  • (Short-term)

    (Long-term) (Standardization)

    Special

    Common

  • 6 x

    ()

    ()

    x x

    1

    )( 2

    n

    XX

    SIGMA SIGMA (Uniformity)

  • 6

    LSL USL T= X

    8

    12

    Cp

    1.00

    3

    1.33 4

    2.00 6

    6 (3.4 ppm)

  • SIX SIGMA

    +1 +2 +3 +4 +5 +6 -1 -2 -3 -4 -5 -6

    USL LSL

    SIXMA DPMO

    2

    3

    4

    5

    6

    308,537

    66,807

    6,210

    233

    3.4 Six Sigma

    Performance

  • SIX SIGMA Six Sigma

    1 : (Focus on the customer)

    Six Sigma

    2 : (Data and Fact-Driven Management)

    Six Sigma

    3 : (Process focused management)

    Six Sigma (ie. Where the action is)

    4 : (Proactive management)

    Six Sigma ?

    5 : (Boundary less collaboration)

    Six Sigma supply chain process

    6 : (Drive for perfection)

    Six Sigma (Break-through)

  • METRIC

    First time yield

    Final yield

    (DPPM) rework

    Throughput yield

    Rolled throughput yield

    DPMO

    Z score

    Cp , Cpk

    Metric Metric Six Sigma

    ( )

  • Baseline

    Benchmark

    Time

    dpmo

    Baseline : Entitlement : Benchmark :

    Entitlement

  • 6

  • (2)

    &

    WHAT

    WHERE ( )

    WHEN

    HOW MUCH

    HOW DO I KNOW

    WHAT is wrong

    WHERE it happened

    WHEN it occurred

    To WHAT EXTENT and

    I KNOW THAT BECAUSE

  • 6 Sigma

  • ?

  • 3

    9/9

    1

    10

    /91

    10

    /91

    11

    /91

    12

    /91

    1/9

    2

    2/9

    2

    3/9

    2

    4/9

    2

    5/9

    2

    6/9

    2

    7/9

    2

    8/9

    2

    9/9

    2

    10

    /92

    11

    /92

    12

    /92

    1/9

    3

    2/9

    3

    3/9

    3

    4/9

    3

    5/9

    3

    6/9

    3

    7/9

    3

    20:00

    22:00

    24:00

    26:00

    28:00

    30:00

    32:00

  • 9/9

    1

    10

    /91

    10

    /91

    11

    /91

    12

    /91

    1/9

    2

    2/9

    2

    3/9

    2

    4/9

    2

    5/9

    2

    6/9

    2

    7/9

    2

    8/9

    2

    9/9

    2

    10

    /92

    11

    /92

    12

    /92

    1/9

    3

    2/9

    3

    3/9

    3

    4/9

    3

    5/9

    3

    6/9

    3

    7/9

    3

    9/9

    1

    10

    /91

    10

    /91

    11

    /91

    12

    /91

    1/9

    2

    2/9

    2

    3/9

    2

    4/9

    2

    5/9

    2

    6/9

    2

    7/9

    2

    8/9

    2

    9/9

    2

    10

    /92

    11

    /92

    12

    /92

    1/9

    3

    2/9

    3

    3/9

    3

    4/9

    3

    5/9

    3

    6/9

    3

    7/9

    3

    20:00

    22:00

    24:00

    26:00

    28:00

    30:00

    32:00

    20:0

    22:0

    24:0

    26:0

    28:0

    30:0

    32:0

    ?

  • 1.

    2.

    3.

  • VS

    9/9

    1

    10

    /91

    10

    /91

    11

    /91

    12

    /91

    1/9

    2

    2/9

    2

    3/9

    2

    4/9

    2

    5/9

    2

    6/9

    2

    7/9

    2

    8/9

    2

    9/9

    2

    10

    /92

    11

    /92

    12

    /92

    1/9

    3

    2/9

    3

    3/9

    3

    4/9

    3

    5/9

    3

    6/9

    3

    7/9

    3

    20:00

    22:00

    24:00

    26:00

    28:00

    30:00

    32:00

    ?

  • 40

    A 40 Deliveries

    -0.5

    0

    0.5

    1

    1.5

    2

    2.5

    3

    3.5

    4

    4.5 B 40 Deliveries

    Days from

    Target

    :

    ?

  • =supplier A

    =supplier B

    Time Plot of Suppliers A and B Late Deliveries (40 weekly deliveries each)

    -0.5

    0

    0.5

    1

    1.5

    2

    2.5

    3

    3.5

    4

    4.5

    1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39

    ?

  • : :

  • ?

  • 1.

    2.

    2.1 5G

    Genba = ()

    Genbutsu = ()

    Genjitsu =

    Genri =

    Gensoku =

    2.1 4

    -

    -

    -

    -

  • (Potential cause) (Root cause/critical cause)

    ()

    ()

    Graph

    Histogram

    Scatter plot

    2 Sample t-test

    ANOVA

    Regression

    Contingency table

  • Yes

    No

  • JURAN

    (Human Control)

    (Non Human Control)

    (Self Control)

    (Management Control)

  • (timing) (Stage)

    100%

    ()

    SPC

  • POKA-YOKE

    YOKE () (Proof)

    POKA ()

    POKA-YOKE (Mistake-proofing) (Foolproof)

    POKA-YOKE : - -

    -

    -

  • NON TECHNICAL MISTAKE PROOFING

    COLOR CODING OF CHANGE PARTS WUPPERTAL

    Before 4 different types of parts needed for

    the conveyor belt of a packaging line

    80 parts per belt

    all the same color but different in shape

    one wrong part could result in deformed

    tampons and or missing tampons

    After through color coding of the different

    parts, misplacments are eleminated

  • NON TECHNICAL MISTAKE PROOFING

    EXAMPLE: UPGRADE WORK INSTRUCTIONS

    37

    BEFORE AFTER

    Simplified & Intuitive Instructions Strengthened Correct Operations

    Also Improved Training Delivery Effectiveness!

  • NON TECHNICAL MISTAKE PROOFING

    EXAMPLE: VISUAL AID & CENTER LINES

    38

    What is missing? Normal pressure range

    Normal speed of pump range

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