Lower Upper
Process Mean
Spec. Limit Spec. Limit
Six Sigma:
Statistically
Visualized
The term “Six Sigma” is based on a statistical
concept: defective items can be minimized by
maintaining 6 standard deviation (6 “sigma’s”)
between the process mean (average) & its upper &
lower specification limits. 1.5σ shift 1.5σ shift
Six Sigma also accounts for the tendency of
processes to degrade over the long term: A Six
Sigma process can tolerate a “shift” of 1.5 standard
deviation and still maintain a “safety cushion” SIX SIGMA
between the process mean & its specification limits. PROCESS
6σ 5σ 4σ 3σ 2σ 1σ 0 1σ 2σ 3σ 4σ 5σ 6σ
Six Sigma: Statistically Visualized
LOWER SPEC. UPPER SPEC. LIMIT
PROCESS MEAN
LIMIT
1.5σ SIX SIGMA PROCESS 1.5σ
shift shift
6σ 5σ 4σ 3σ 2σ 1σ 0 1σ 2σ 3σ 4σ 5σ 6σ
Levels of Six Sigma
SIX SIGMA LEVEL % ACCURACY DPMO
VIRTUAL 6 99.9997% 3.4
PERFECTION
5 99.98% 233
4 99.4% 6210
GOOD 3.5 97.7% 22,700
3 03.3% 66,807
IMPROVEMENT 2 69.1% 308,537
NEEDED
Six Sigma Roadmap
Define
1
Build project from
nonconformance,
feedback & audits
Measure
SIX SIGMA IMPROVEMENT SIX SIGMA DESIGN (DFSS)
Collect
measurements
5
Define Define
2
Measure Control/Verify Measure
Monitor live
Analyze dashboards Analyze
Improve Analyze Design
Analyze processes
Control online (OLAP) Verify
4
Improve/Design
Correct, design
3
train & document
Breakthrough Strategy
SIX SIGMA STANDARD METHODS
(Optimal Improvement) (Gradual Improvement)
Breakthrough Gradual Improvement
Improvement
• Kaizen
• Re-Engineering
• TQM
• Current Tools & Approaches
Improvement Quota
Duration in Years
1 2 3 4 5
GATE A GATE B GATE C GATE D GATE E
Process
Development
HIGH SUCCESS
Production
RATE
Innovation Assay Tech Transfer 2 Tech Transfer 3
Documentation
QA/QC
RA
REDUCED TIME TO MARKET DECREASED COSTS
Design for Six Sigma (DFSS)
D EFINE Define project goals
Customer analysis/
risk assessment
Assemble team
M EASURE Capture vice of customer Determine project schedule Determine risk assessment
A NALYZE Develop CTQ’s Review project schedule Review risk assessment
D ESIGN Develop models Determine CTQ’s
O PTIMIZE Review CTQ’s Tolerance testing Design optimization
V ERIFY
Product comparison against
initial specifications
Document development
Area of Implementation
Expand areas of implementation to suppliers and customer. Processes do not
begin and end in the company, they end with supplier and customers.
Implementation Implementation Implementation
AREA 02 AREA 01 AREA 03
SUPPLIER OUR COMPANY CUSTOMER
Insert a text about P&G Sourcing Production Distribution Insert a text about customer
supplier role in six sigma - role in six sigma - area of
area of implementation Logistics implementation process.
process.
Documentation
Organization
Human Resource/Development
12-Step Implementation
Model
Persuasion of the chairman of the board Step 01
Nomination of the champion Step 02
BEGINNING
Persuasion of the top management Step 03
Program development Step 04
Selection of Master Black Belt, Black Belts and Green Belts Step 05
EDUCATION Implementation of training courses Step 06
First results Step 07
Assessment of process performance Step 08
MEASUREMENT Set targets Step 09
Call for result Step 10
Maintenance of Six Sigma Step 11
IMPROVEMENT
Endurance and continuous improvement Step 12
Six Sigma 7X7 Toolbox
QUALITY CONTROL MANAGEMENT
DESIGN TOOLS STATISTIC TOOLS PROJECT TOOLS LEAN TOOLS CUSTOMER TOOLS
TOOLS TOOLS
Check forms (including
Robust design Factorial attempt Network plan Standardization Kano-Model Decision tree
measure plan)
Quality Function Project & team
Skill analysis Waste analysis Requirement structuring Histogram Affinity diagram
Development (QFD) description
TRIZ Regression analysis CTQ-Analysis Shortage analysis House of quality Pareto-Diagram Relations diagram
Pugh concept Cause-and-effect
Multivariate analysis Tree diagram Flow diagram Taguchi loss function Tree diagram
selection diagram
Statistical tests
FMEA / VMEA Skill analysis Supply chain matrix Customer interviews Graphic comparison Matrix diagram
(ANOVA, ANOM)
Fault tree analysis
Hypothesis testing Cost-benefit analysis Set-up time analysis Customer surveys Relations diagram Matrix-Data-Analysis
(FTA)
Tolerance design Gage R&R analysis Control charts Red-Tag-Analysis Conjoint analysis Control charts Network plan technique
Six Sigma Methodology - DMAIC
M EASURE PHASE Practical Problem
Lean Six Sigma Methodology
Characterization
A NALYZE PHASE Analytical Problem
D ESIGN PHASE
I MPROVE PHASE Analytical Solution
Optimization
C ONTROL PHASE Practical Solution
Six Sigma Methodology - DMAIC
Collect relevant data about Determine the optimum values
the process and the problem for key contributing process
inputs
MEASU IMPROV
RE E
D M A I C
ANALYZ CONTRO
DEFINE
E L
Define the problem and the ideal Identify the cause-effect relationship Establish standards to
in terms of the target to achieve between inputs and outputs. sustain improvements in the
long run.
Voice of Customer & Voice of
Process
Understand the problem that
Practical Problem
impacts business performance Realize Recognize
DEFINE
Identify the problem
Statistical Problem
with data and facts
01
Statistical Solution
Find out a data-driven CONTROL MEASURE
and reliable solution
05 02
Provide a solution to
Practical Solution
increase profit, reduce
waste
Create a system to sustain
Control Plan IMPROVE ANALYZE
a long-term solution
04 03
Measure and reap the
Results
benefits of financial successes
Six Sigma Methodology - DMADV
FRAMEWORK DESCRIPTION
Verify that the new process
List more detailed
Collect VOC’s of the target Make a final design will property fulfill the
Define what kind of function for achieving
process and convert them plan, and complete customer’s needs, &
project we’ll do. the CTQ, and decide
to new process’ CTQs the new phase sustain improvement in the
basic design concept
long run
DEFINE MEASURE ANALYZE DESIGN VERIFY
“I want to gather customer
5-How Analysis, SIPOC Development on Made an SOP
Project Chart, QBS data & sales data in one
Analysis and Value Excel (videos about (Standard Operating
and Gantt Chart place & generate useful info.
Stream Map this topic will come) Procedure) in Excel
& tools for my salesforce
METHODS USED IN THIS
PROJECT
The 5 Phases of DMADV
01 02 03 04 05
DEFINE MEASURE ANALYZE DESIGN VERIFY
• Project team or • Identify & segment • Implement customer • Create detailed • Review performance
determine project customers req. into design design of the new product of
charter • Identify & analyze concept • Develop robust the process (piloting)
• Determine objective & customer req. • Rate design concept design with optimal • Implementation of
scope of project • Compare existing (QFD, TRIZ…) target value/cost work preparation &
• Interface to other product with • Evaluation under benefit ratio production
processes/define internal/external application of FMEA • Apply DOE • Continuously monitor
sector & provide benchmarking (target costing…) results of new process
resource • QFD for CTQ’s
Project Status Sheet
Location Project Number
Process Project Start Date
Customer of Process Project Conclusion Date
Team (Name/Division) Project End Date
SUBJECT/REASON PROCESS DATE INITIAL SITUATION ACTUAL STATUS OBJECTIVES
Error rate (PPM) & profit (%RTY)
Project Objectives
And/or cycle time
IN Focus
OUT Focus
Financial benefit of the project
Cash
Saving Potential
Prevented error costs
Cost by non-conformance
Non-financial benefit of the project or waste (EUR)
Investments/Costs
-
Control Chart Test Decision Tree
No
X-Bar & R Chart
Subgroups
Subgroups
>6 ?
Individual X-Bar & S Chart
Yes
or
Continuous Charts
subgroups
?
START HERE
Individuals I & MR
What type
No
of data ?
U Chart
Constant
Counts of defects subgroup
size ?
C Chart
What is Yes
Discrete Charts being
counted ? No
P Chart
Constant
Proportion
subgroup
defectives
size ?
nP Chart
Yes
Six Sigma Control Chart
80
75 FLAT TIRE
70
65
60
55
TIME (MINUTES)
50
45
40
35
UCL = 31.1
30
25
20
Avg = 17.80
15
10
LCL = 8.90
5
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
DAY NUMBER
Six Sigma Control Chart
Time (minutes) Prepared By Date Document No.
Process Name Approved By Date Initiation Date
Project ID Process Owner Revision No.
Project Scope Page Number of/to Revision Date
CTQ Specification
Unit of Applicable
Process Specific Data Measure Who Where Corrective
Measure - Sample Size Frequency Standard
Step Character Description Method Measures Recorded Action
KPIV KPOV LSL USL ment Operating
Outer Optical Replace
Polishing 0.0004 0.0006 mm Variables 10 parts/lot Hourly Operator X-bar PM-005
Diameter comparator paper
Time Late = Each Each Prod. Conduct
Delivery Due date 98% 100% Attribute P chart PC-001, 002
delivery 1 defect delivery delivery Control 5 why
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