Chapter 1.

1
Introduction to Six Sigma

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 1.1- Introduction to 6s

What is 6s ?
• Is an “Organization-Wide Initiative” to achieve zero
defects and reduce wastes (“Muda”) and variations in the
processes
• Top Management commitment and strong review
mechanisms are the key to the success of the Six Sigma
initiative
• Trained people who are skilled in understanding the
processes and also has the skill in the selection and
application of Six sigma tools to achieve zero defects are
essential in this initiative
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 1.1- Introduction to 6s

What is 6s ?

• This is an initiative which will lead the Organization in the

long run to achieve “Six Sigma levels” in each of their
manufacturing/service processes
• Successful Organization wide deployment of Six sigma
will take a minimum of three years

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 1.1- Introduction to 6s

Origin of 6s initiative

• Six Sigma initiative was first developed by Mr. Bill Smith,

who was working as Quality Manager at Motorola
• With a strong commitment from Mr. Bob Galvin, then
CEO of Motorola, the implementation of the initiative
began in 1986
• This initiative helped Motorola win the first Malcolm
Baldrige Award in 1988

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 1.1- Introduction to 6s

Origin of 6s initiative

• Several of the major companies in the world have

adopted Six Sigma since then ....

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 1.1- Introduction to 6s

Birds eye view of 6s

Reduced defect levels and

Variations in any process
Methodology
• Data based decision making . No “Atmospheric Analysis”
•Use Shainin Design of Experiments (DOE) as the Data based tool for zeroing in on the
root cause(s) of the variations
•Structured troubleshooting done by cross functional teams having “Process Knowledge”
•Each team is assigned a project (called “Six sigma project”) which when resolved will lead
to substantial savings for the Organization
•Project selection done by “TOP MANAGEMENT”
•Each Project should be completed in a maximum duration of Three months
•Process adopted is “DMAIC”
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 1.1- Introduction to 6s

6s Focus
Processing Power
material Speed factor

Input Output
Material Process Product

•Defect reduction projects

•Cost reduction projects (Process Optimization)

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 1.1- Introduction to 6s

6s Focus - Example

1. Ra
Rough ground
Matl. Finish Grinding 2.
3.
Dia
Roud ness

•Zero defects after grinding

•Setup-time reduction in grinding
•Process characterization of parameters (E.g.: Do we need
the dressing frequency of 10 nos or can it be increased
•Input material – Tolerances optimization
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 1.1- Introduction to 6s

6s Focus - Rolled Throughput Yield (RTY)

Forging Y1 Normalizing Y2 R/blank turn Y3 Final boring

100% 90% 100%

Y6 Y5 Y4
Hobbing Drilling Broaching Final OD
& Face turn
80% 100% 100%
100% Y7

Shaving Y8
100%

RTY Y1 x Y2 x Y3 x Y4 x Y5 x Y6 x Y7 x Y8
RTY 1 x 0.9 x 1 x 1 x 1 x 0.8 x 1 x 1 = 0.72 x 100 =72%
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 1.1- Introduction to 6s

Funneling – Case 1

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 1.1- Introduction to 6s

Funneling – Case 2

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 1.1- Introduction to 6s

Funneling – Case 3
Cause-and-Effect Diagram

Measurements Materials Personnel

Hardness

Flatness Loading method

Bore taper

Clamping Pr
??
Spindle brg.wear

Locator wearout

Fixture wearout
Environment Process Machines

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 1.1- Introduction to 6s

Funneling

Many potential options

to choose from

To go through many process

.to narrow down options

Few potential outcomes

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 1.1- Introduction to 6s

Funneling – Case 1

Side Face unclear

DOE # 1
Gas Nitriding
DOE # 2

Pre-Nitriding

Process Capability Sixpack for Response

DOE # 3 115
I-MR-R Chart
UCL=115.8
Capability Histogram

100

Mean
Mean=93.9

Current in
85

70 LCL=71.97
50 90 130

30 Normal Prob Plot

UCL=26.94

Pre-Nitriding
Mov.Range

20

10
R=8.244

0 LCL=0
50 90 130

75
StDevs Capability Plot
UCL=72.29 Betw: 3.196 Process Tolerance
Within: 14.698
Between/Within
50 Total: 15.042 I I I
Range

R=34.19
Overall: 14.965 Overall
I I I
25 Capability
Cp: 1.88 Specifications
I I
0 LCL=0 Cpk: 1.69
0 170
Pp: 1.89
Subgroup 0 1 2 3 4 5 6 7 8 9 10 Ppk: 1.70

14 B Vs C
 1.1- Introduction to 6s

Funneling – Case 2

Debond Defect

DOE # 1
Gap between Lugs

Process Capability Sixpack for Response

I-MR-R Chart Capability Histogram

115 UCL=115.8

100

Mean
Mean=93.9
85

70 LCL=71.97
50 90 130

30 Normal Prob Plot

UCL=26.94
Mov.Range

20

10
R=8.244

0 LCL=0
50 90 130

75
StDevs Capability Plot
UCL=72.29 Betw: 3.196 Process Tolerance
Within: 14.698
Between/Within
50 Total: 15.042 I I I
Range

R=34.19
Overall: 14.965 Overall
I I I
25 Capability
Cp: 1.88 Specifications
I I
0 LCL=0 Cpk: 1.69
0 170
Pp: 1.89
Subgroup 0 1 2 3 4 5 6 7 8 9 10 Ppk: 1.70

15 B Vs C
 1.1- Introduction to 6s

Funneling – Case 3

Bore taper

DOE # 1
Boring process
DOE # 2

Fixture web thickness

Process Capability Sixpack for Response

I-MR-R Chart Capability Histogram

115 UCL=115.8

100

Mean
Mean=93.9
85

70 LCL=71.97
50 90 130

30 Normal Prob Plot

Mov.Range UCL=26.94

20

10
R=8.244

0 LCL=0
50 90 130

75
StDevs Capability Plot
UCL=72.29 Betw: 3.196 Process Tolerance
Within: 14.698
Between/Within
50 Total: 15.042 I I I
Range

R=34.19
Overall: 14.965 Overall
I I I
25 Capability
Cp: 1.88 Specifications
I I
0 LCL=0 Cpk: 1.69
0 170
Pp: 1.89
Subgroup 0 1 2 3 4 5 6 7 8 9 10 Ppk: 1.70

16 B Vs C
 1.1- Introduction to 6s

Terminologies used in 6s
• BIG Y = Main Response for the Problem

• X = Cause(s) that are not controllable. These are also

called as Intermediate “Y”s

• Root X’s – Root cause(s) that are controllable by

implementing process improvement actions

• SSV’s Suspected Source of Variations

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 Y = f (X)

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 1.1- Introduction to 6s

Funneling – Case 1 Y=f(X)

Unclear after Side face grinding

Y = f (X)

• Y = Unclear after side • X’s are

grinding DOE#1 • Side face grinding
• Input material

After application of DOE tool #1, cause found as Input

material, which is not controllable
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 1.1- Introduction to 6s

Funneling – Case 1 Y=f(X)

Y = f (X)

• Y = Input material • X’s are

• Gas Nitriding
DOE#2 • Pre-Nitriding

After application of DOE tool #2, cause found as Pre-nitriding,

which is not controllable
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 1.1- Introduction to 6s

Funneling – Case 1 Y=f(X)

Y = f (X)

• X’s are
• Y = Pre-Nitriding DOE#3 • Current
• Time
• Concentration

After application of DOE tool #3, cause found as Current,

which is CONTROLLABLE
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 1.1- Introduction to 6s

Funneling – Case 2 Y=f(X)

Debonding after casting

Y = f (X)

• Y = De-bond • X’s are

DOE#1 • Many as per
C&E diagram

After application of DOE tool #1, cause found as Gap

between lugs which is Controllable
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 1.1- Introduction to 6s

Funneling – Case 3 Y=f(X)

Bore taper variation after boring

Y = f (X)

• X’s are
• Y = Bore Taper DOE#1 • Input material
•Boring process

After application of DOE tool #1, cause found as Boring

Process, which is not controllable
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 1.1- Introduction to 6s

Funneling – Case 3 Y=f(X)

Y = f (X)

• Y = Bore Taper • X’s are

DOE#2 • Machine
•Fixture
•Locators
•Process design

After application of DOE tool #1, cause found as Fixture web

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thickness, which is Controllable
 1.1- Introduction to 6s

Why the name 6s

Lower Nominal Upper
Spec Limit Target Spec Limit

In this case,
6sigma = 50% Tolerance
Defect level = 3 ppb
assuming the process is centered
This level is called 6 Sigma level

Process Mean
6s
Estimate Part to Part variation is represented by 6s
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 1.1- Introduction to 6s

Why the name 6s

Nominal Upper
Lower Target
Spec Limit Spec Limit

In this case,
6sigma = Tolerance
Defect level = .27% assuming
the process is centered
This level is called 3 Sigma level

Defects

Process Mean
6s
Estimate Part to Part variation is represented by 6s
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 1.1- Introduction to 6s

Why the name 6s

Estimated Part to Part variation as %
to Tolerance Defect (PPM/PPB) Sigma level
(6s as % of Tolerance)
6s =Tolerance 2700 3

6s = 75 % of Tolerance 60 4

6s = 60 % of Tolerance 28 ppb 5

6s = 50 % of Tolerance 3 ppb 6

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 1.1- Introduction to 6s

Why the name 6s

Estimated Part to Part
variation as % to Defect
Tolerance Sigma level
(PPM/PPB)
(6s as % of Tolerance)
6s =Tolerance 2700 3 Cp=Tol /6s Cp=1/1=1

6s = 75 % of Tolerance 60 4 Cp=Tol /6s Cp=1/0.75=1.33

6s = 60 % of Tolerance 28 ppb 5 Cp=Tol /6s Cp=1/0.6=1.67

6s = 50 % of Tolerance 3 ppb 6 Cp=Tol /6s Cp=1/0.5=2.0

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 1.1- Introduction to 6s
What it means to be @ 6s
99%Good enough - At 3.8s?
20,000 lost mails per hour
Unsafe drinking water almost 15
minutes each day
5,000 incorrect surgical
operations per week
2 short or long landings at most
major airport daily
200,000 wrong drug
prescriptions each year
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99.99966% Good – At 6s
7 lost mails per hour
One minute of Unsafe drinking
water every seven months
1.7 incorrect surgical operations per
week
One short or long landing at major
airports every five years
68 wrong drug prescriptions each
year
 1.1- Introduction to 6s

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 1.1- Introduction to 6s

Key Points

• 6s is all about reducing & eliminating wastes in all the

process
• Methodology adopted is “Funneling”
• The technique used is to Funnel is “Design of Experiments
“ (DOE)
• Object is to improve the RTY (Rolled Through Yield) of all
the products manufacturing in the Organization
• Initiated by Motorola which helped them in improving the
process yields and win Malcom Baldridge award
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 End of Chapter 1.1

Clarifications if any

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