six sigma -an awareness programme
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S I X S I G M S I X S I G M AA
A n A w a r e n e s s P r o g r a m m e
VM Rao, Transmission PU
Mahindra & Mahindra Ltd., Automotive Sector, Kandivli
Six Sigma: An Awareness
A w a r e n e s s T o u r• Six Sigma: The History• Why Six Sigma is better than other Quality Initiatives ?• What is Sigma ?• What is Variability ?• The 6 Problem Solving Methodology
Six Sigma: The History
Cost of Poor Quality
Prevention Cost Appraisal Cost
Lost Managemen
t Cost
Lost Opportunity,
Lost Assets Cost
Rerun Cost
Lost Business, Goodwill cost
Maintenance Cost
Lost Credibility Cost
Proj
ect
Rew
ork
Cost
Organisation Ocean
Six Sigma: History
99% Quality means………• 5000 incorrect surgical operations per week !• 200,000 wrong drg prescriptions each year !• 2 Short or Long landings at Airport each day !• Unsafe Drinking Water for 15 min/day !• 20,000 lost artcles of mail per hour !• No electricity for 7 hrs per month !
What is Good Quality ?…… 99% ??
Six Sigma: History
????!!!
Motorola
1/20 th of Defects !!
Motorola’s Quassar TV set plant in US sold to Japanese for the reasons of poor Productivity & Yield started doing extremely well under Japanese management !!! TV sets were produced with 1/20th the no. of defects that were produced by Motorola !They did this using the same workforce, technology & design… making it clear that the problem was Motorola’s management !
Six Sigma: History
If a product was found defective & corrected during the production process, other defects were bound to be missed and found later by the customer during early use of the product…. However, when the product was manufactured error free, it rarely failed during early use by the consumer…....
A Paper by Bill Smith….
In 1986, Motorola went full scale on Six Sigma…!!
In 1985, Bill Smith, an engineer at Motorolapresented a paperwhich concluded that….
Six Sigma: What’s New It?
How this Initiative is More Effective ??- Active Leadership: Top Management’s Involvement- Business Unit Vs Corporate wide Initiative - Customer Focussed “CTQ”- Direct Link to Business Results- Mfg View of Quality Vs “Q” in All Functions- Bottom Line Improvement- Incremental Vs Breakthrough Improvements
Six Sigma: What’s New It?
- Tells What to Do & How to Do…… - Mandate Use of Statistical Techniques - Multiple Indices (Local + Global) - Effective Project Management- Special Metrics (DPU, DPMO, etc.)- Special Roles (Black Belt, Green Belts, Champion)- Best People for ‘Q’ Initiatives- Inductive Training
Six Sigma: Special Roles
ChampionMaster
Black Belt
Black Belts
Green Belts
6 Deployment Strategy
What is Six Sigma ?
What is Sigma ( ) ?
Xi = 10, 12, 14 Xbar = 12
=(Xi-12) Deviation
2Variation
n-1Variance
Std. Devn. Sigma ()
TargetLSL USL
Parts out of Specs
A < 3 Situatio
n
What is 6 Sigma ?
Cp<1
TargetLSL USL
All in Specs
A 3 Situatio
n
What is 6 Sigma ?
Cp=1
TargetLSL USL
Only 50% of
tol. used
A 6 Situatio
n
What is 6 Sigma ?
Cp=2
If the Pilot can always land the Aircraft within 50% of Runway area…… He is of Six Sigma Quality !
LSL USLTarg
et
What is 6 Sigma ?
50% of Tol Band
LSL USL
-6 -2 -1 +1 +2 +3 +4 +5 +6-5 -4 -3 Xbar
Spec Limit Percent Defective ppm ± 1 68.27 3,17,300 ± 2 95.45 45,500 ± 3 99.73 2,700 ± 4 99.9937 63 ± 5 99.999943 0.57 ± 6 99.9999998 0.002
What is 6 Sigma ? Without
ProcessShift
What is 6 Sigma ?
LSL USL
-6 -2 -1 +1 +2 +3 +4 +5 +6-5 -4 -3 Xbar
Spec Limit Percent Defective ppm ± 1 30.23 6,97,700 ± 2 69.13 3,08,700 ± 3 93.32 66,810 ± 4 99.3790 6,210 ± 5 99.97670 233 ± 6 99.999660 3.4
With± 1.5Shift
-1.5 +1.5
Sigma Table
Cp DPMO Sigma0.5 500,000 1.50.55 440,000 1.650.6 382,100 1.80.65 326,400 1.950.7 274,300 2.10.75 226,600 2.250.8 184,100 2.40.85 146,900 2.550.9 115,100 2.70.95 88,510 2.851 66,810 31.02 59,380 3.061.04 52,620 3.121.06 46,480 3.181.08 40,930 3.241.1 35,930 3.31.12 31,440 3.361.14 27,430 3.421.16 23,850 3.481.18 20,680 3.541.2 17,860 3.6
Cp DPMO Sigma1.22 15,390 3.661.24 13,210 3.721.26 11,300 3.781.28 9,642 3.841.3 8,198 3.91.32 6,947 3.961.33 6,210 41.34 5,868 4.021.36 4,940 4.081.38 4,145 4.141.4 3,467 4.21.42 2,890 4.261.44 2,401 4.321.46 1,988 4.381.48 1,641 4.441.5 1,350 4.51.52 1,107 4.561.54 904 4.621.56 736 4.681.58 598 4.741.6 483 4.8
Cp DPMO Sigma1.62 390 4.861.64 313 4.921.66 233 51.68 200 5.041.7 159 5.11.72 126 5.161.74 99.6 5.221.76 78.4 5.281.78 61.5 5.341.8 48.1 5.41.82 37.5 5.461.84 29.1 5.521.86 22.5 5.581.88 17.4 5.641.9 13.4 5.71.92 10.2 5.761.94 7.8 5.821.96 5.9 5.881.98 4.5 5.942 3.4 6
The Six SigmaProblem Solving
Sequence
The Types of Problems?
Unknown Known
Know
nU
nkno
wn
Root Cause
SolutionDDCC
BBAA
Simple Problems
Really WorthSolving &
Challenging
Question ofImplementation
Require HighLevel of Tech.
Types of Problem Solvers
The Problem Solving
Type
The ------ Type
The Some One
Else’sFault Type
Self Negating,Despairing
Type
VariationLSL
USL
M
What is Variability?
LSL
USL
M
Off-Target
What is Variability?
LSL
USL
M
Variation+Off-Target
What is Variability?
LSL
USL
M
Centered+No Variation
The Ideal Process
What is Variability?
+=Variation
Variation
OffTarget
Off-Target
Variation+Off-Target
Variability
Instability
Target
LSL USL
Spec Width(Engg Spec) Process
Width
Cp =Spec Width
Process width=
DenotesVariation
Cp
What is Cp, Cpk
What is Cp, Cpk
Target
LSL USL
Dist fromSpec Dist from
Proc Edge
Cpk ={Process Centre to Spec Edge}
{Process Centre to Process Edge} =Denotes
Off-Target
Cpk
Off-Target but LeastVariation
Off-Target & High
VariationNear-Target
but HighVariation
The Ideal One !
What is Variability?
6 Problem Solving Sequence
6
1
2
3
4
5
DMAICCycle
(What to Do?)
6 Problem Solving Sequence
56
1
23
4
C
S
ICSI
Cycle(How to Do?)
6 Problem Solving Sequence
S o l v e
I m p l e m e n t
C h a r t
It tells you what your
problem is…and how severe
it is...
It is a 5-LevelProblem Solving
Sequence…T-L-P-E-F
Not just solve…but
institutionalizethe changes
Problem Solving Sequence- Snap Shot
P+c+Pareto
Analysis
Conurbation Margin
Analysis
ProcessMapping
ParetoAnalysis
C+ParetoAnalysis
CorrelationAnalysis
ValueAnalysis
Multivariate
Chart
Bathtub
Curve
Component
Swap
Avg-RangeChart
Proportion
Chart
IndividualsChart
Multi-VariChart
Multi-StationChart
Control Modify RecreateOptimize
Brainstorming Process Flow DiagramCause & Effect Diagram
CorrelationAnalysis
Subjective Rating & Analysis
ScreeningExperiments
ContingencyTable Analysis
FactorialExperiments
HybridExperiments
ObservationalStudies
Response SurfaceExperiment
Monte-CarloSimulation
Dual Alarms
for Action
Mechanized
Solution
ShutdownProcess
SOP + Audit
SPC ofInputs
SPC ofResults
Alarm for
Action
1. Chart
2. Solve
3.Implement
TacticList the Variables
Assess
Prioritise
Fine Tune
Problem Solving Sequence- Snap Shot
P+c+Pareto
Analysis
Conurbation Margin
Analysis
ProcessMapping
ParetoAnalysis
C+ParetoAnalysis
CorrelationAnalysis
ValueAnalysis
Multivariate
Chart
Bathtub
Curve
Component
Swap
Avg-RangeChart
Proportion
Chart
IndividualsChart
Multi-VariChart
Multi-StationChart
Control Modify RecreateOptimize
Brainstorming Process Flow DiagramCause & Effect Diagram
CorrelationAnalysis
Subjective Rating & Analysis
ScreeningExperiments
ContingencyTable Analysis
FactorialExperiments
HybridExperiments
ObservationalStudies
Response SurfaceExperiment
Monte-CarloSimulation
Dual Alarms
for Action
Mechanized
Solution
ShutdownProcess
SOP + Audit
SPC ofInputs
SPC ofResults
Alarm for
Action
1. Chart
2. Solve
3.Implement
6 Problem Solving Sequence
P+c+Pareto
AnalysisConurbation
MarginAnalysis
ProcessMapping
ParetoAnalysis
C+ParetoAnalysis
CorrelationAnalysis
ValueAnalysis
Multivariate
Chart
BathtubCurve
ComponentSwap
Avg-RangeChart
ProportionChart
IndividualsChart
Multi-VariChart
Multi-StationChart
Step 1 : Chart
6 Problem Solving Sequence
Level 1: Select the “Tactic”
Control
Modify
Recreate
Optimize
Step 2 : Solve
6 Problem Solving Sequence
Level 2: List the Variables
Brainstorming
Process Flow Diagram
Cause & Effect Diagram
Step 2 : Solve
6 Problem Solving Sequence
Level 3: Prioritize the Variables
CorrelationAnalysis
Contingency
TableAnalysis
SubjectiveRating &Analysis
ScreeningExperiments
Step 2 : Solve
6 Problem Solving Sequence
Level 4: Evaluation of Variables / Parameters
FactorialExperiments
ObservationalStudy
HybridExperiment
Step 2 : Solve
6 Problem Solving Sequence
Step 2 : Solve
Level 5: Fine-tuning / Refining the Process
ResponseSurface
Experiment Monte-Carlo
Simulation
6 Problem Solving Sequence
Step 3 : Implement
Dual Alarms
for Action
Mechanized
Solution
ShutdownProcess
SOP + Audit
SPC ofInputs
SPC ofResults
Alarm forAction
Six Sigma: An Awareness
Frequently Asked Questions
Some Clarifications on Six Sigma
Q1: Is it necessary to initiate Six Sigma all over the organisation or few ?
A: Never. Choose a Pilot Project at a Pilot Location. Taste the success and then spread across the organisation.
Some Clarifications on Six Sigma
Q2: Is it compulsory to have a Black Belt for initiation of a Six Sigma programme ?
A: Not necessary. If one has knowledge of all the tools mentioned in Six Sigma and is comfortable with the methodology, even with the knowledge of Champion also Six Sigma projects can be taken up.
Q3: Is it necessary that minimum financial gains of a 6 Sigma projects should be in 000’s of $ ?
A: Not necessary. If the company’s turnover itself is some 000’s of $, then what? Use the concept wherever you are uncomfortable with.
Some Clarifications on Six Sigma
Some Clarifications on Six Sigma
Q4: Are calculations of RTY, nRTY, Yield, etc compulsory to begin with ?
A: No. They all are confusing terms came along with Six Sigma. Concentrate on the methodology for the company’s benefits
Some Clarifications on Six Sigma
Q5: Can short term projects can be taken ?
A: Yes. After all it depends on the co’s necessities. For e.g. Wipro has short term projects called Turbo Projects.
Six Sigma: An Awareness
Popular Six Sigma Software:• Minitab• Statgraphics• SAS-Jmp
Popular Six Sigma Sites:• isixsigma.com• informintl.com• bn.com• multiface.com
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