Six Sigma Project Guideline sigmaLogic

18
100 100
Mean 3,344
StDev 0,5489
D
16 N 100

A
80 80

Identify Project Graphical Data Evaluation

14

Relevance of Topic: 36% 12

Percent
60 60

Frequency
10

8
e f i n e

n a l y s e
40 40 6

collect project topics 20 20

4

a) Pareto-Chart
ab
2

0 0 0

Y d ng ng ng n t d
2,4 2,8 3,2 3,6 4,0 4,4

Y
Suitable for: Six Sigma
Choc-Cookie

evaluate topics X
6

5
e
ba
w
ro
w
ro
w
ro ro
ke
bu
rn
ee
de

cd
6
b) Histogram X

Y_Choc-Cookie-Taste first Week

4

prioritize topics Z
4
2
c) Boxplot Z

Data
3
0

Own contribution: 80% select project S 2

1
-2
d) Time Series Plot S
P Choc-Cookie Cocos-Cookie Van-Cookie -4
3 6 9 12 15 18 21 24 27 30 P

Process-Capability Process-Control
Define Project Process Capability Report for Yt1 _Cookie-Weight I-MR Chart of Y_Consumption_per_Day
Summary Report
Process-Capability/ -Control
process and output Yield%/ DPU/ DPMO
Is the process mean stable? Comments
Evaluate the % of out-of-control points.
LSL Target USL The process mean may not be stable. 5 (15,6%) data points are out of control
0% > 5% on the I chart. Keep in mind that you may see 0,7% out-of-control points by
Process Data Overall chance, even when the process is stable.
LSL 18 Within
Target 20 Yes No

Y Y
USL 22 Overall Capability 15,6%
Sample Mean 20,9507 Z.Bench 0,1 8
Sample N 60 Z.LSL 1 ,26
Z.USL 0,45

Z.Bench (Sigma Level)/ cp/ cpk …

StDev(Overall) 2,3331 5

problem
StDev(Within) 2,04775 Ppk 0,1 5
Cpm 0,26
Potential (Within) Capability Individual and Moving Range Charts

X Z.Bench 0,31
Z.LSL
Z.USL
1 ,44
0,51
25
Investigate any out-of-control points.
UCL=23,92

Individual Value
Cpk 0,1 7
10
_

effect I-MR/ xbar-R/ xbar-S/ P-/ U-Chart

X=5,89

Z 20
-5

LCL=-12,13

UCL=22,14
Z
S S

Moving Range
solution ideas (if present) as baseline of the process
10
1 5,0 1 6,5 1 8,0 1 9,5 21 ,0 22,5 24,0 25,5 __
MR=6,78

Performance
Observed Expected Overall Expected Within 0 LCL=0

P P
PPM < LSL 1 00000,00 1 02992,26 74799,56 1 4 7 10 13 16 19 22 25 28 31
PPM > USL 266666,67 326450,62 3041 79,60
PPM Total 366666,67 429442,89 378979,1 5 N: 32 Mean: 5,8947 StDev(within): 6,0087 StDev(overall): 4,0946

Control limits are estimated using the StDev(within).

SIPOC (Supplier-Input-Process-Output-Customer) Difference Relationship

Input Process Output
Test Hypothesis
structure process into the main Boxplot of Y_Cookie_Weight Scatterplot of Y_Brightness_of_Cookie vs x_Baking_Time
27,5 22

Difference-Hypothesis:
process steps Y 25,0
20

Y
Ya =/≠ Yb

Y _Brigh tness_of_Cook ie
18

Y_C ookie_W eight

22,5

assign inputs and X 16

X
Relationship-Hypothesis:
20,0

Z 14

Z
Input Process Output (intermediate) outputs S
1 7,5 12

S
1 5,0
10

Y =/≠ f(x)
assign supplier and customer
t_1 t_2 10 12 14 16 18 20

P time_of_measurement x_Baking_Time
P

Voice of Customer & Business

VoC/ VoB > CCR/ CBR > CtQ
Root-Cause-Analysis
interview customer/ manager
Requirements and Deviations
derive requirements for outputs Y Y
X identify root-causes x´ X
and evaluate their deviations
Z of the negative influences x on Z
derive problems Y of the output S S
Severity of Problems of Outputs the problems Y
and their severity P P

Project-Charter Project-Charter Solution-Ideas

I
m p r o v e
Business develop solutions to eliminate,
Problem focus on critical problems Y Y Cause Problem Y
Relevance Solution circumvent or adjust parameter
specify their business relevance X (x´) (Y) X
Scope/ Experts Z of the root-causes x´ Z
Belt-Team define scope and objectives S S
Objectives prioritize solutions
Management build a team P P

Input Input-Analysis
M

Design of Experiments (DoE)

identify necessary inputs
e a s u r e

Requirements and deviations specify the requirements
specify negative influences xi of
negative Influences on Problems inputs on the output/ problems Y
Y Y
X Y= f(x) adjust significant/ relevant X
Z Z
S parameters x to optimize Y S
P P

Process-Steps > Activities Process-Mapping & -Analysis

map process steps into activities
Measure 8
Action-List
Y Measure 3 Y
Input, Output, Methods & Resources assign inputs and outputs X x
specify methods & resources Z specify solutions as measures Z
Measure 4
(Who?/ What?/ until When?)
S S
negative Influences on Problems specify neg. influences xm/ xr P P
FMEA

Problems (Y)
(Failure Mode and Effects Analysis)

Cause & Effect-Matrix (C&E)

Risk-Analysis Improvement new Risk-Analysis
Probabili ty of

Probabili ty of
the Probl em

the Probl em
Det ection of

Det ection of
Severity of

Severity of

R R
the Effect

the Effect

Y1 Y2 Y3 Yn
Cause

Cause

actual controls to detect the Failures/

potential Failures/ Problems
Problems
potential Effects of the Failures/ Problems potential Causes of the Failure/ Problem P Countermeasures P
N N
Measure-No.

3
evaluate impact strength of the
Measure (What has to be done?)

FMEA (Failure Mode and Effects Analysis)

10= catast rophic

10= catast rophic

Xi1
Risk-Prior ity-

Risk-Prior ity-
1= always -

1= always -
10= always

10= always
1= never -

1= never -
10= never

10= never

Input
Number

Number
1= no -

1= no -
Rating:

Rating:

Rating:

Rating:

Rating:

Rating:

Which Failures/ Problems can result from the By which existing Controls could the Failure/ How could the trigger of the Failure/ Problem, i.e.

(Xi) Xi2 1 Y Measures? Problem be detected, before it occurs?

...?
What is the Effect of the Failure/ Problem?
...?
Which Influence triggers the Failure/ Problem?
...?
their Root-Causes be eliminated
...? ...? ...?
Y
Xin 4 negative influences of inputs xi, X
1.
Let the Chef weigh 10 g of chocolate for her
special Chocolate Check
can cause caries periodic dental prophylaxis 5

...?

...?
tooth loss 7

...?

...?
sugar/ bacterial plaque 10

...?

...?
350
immediate brushing of teeth after check of
chocolate
7

...?

...?
2

...?

...?
5

...?

...?
70

X
Process-Steps
Xp1 2 methods xr and resources xr on Z ...?

...?
...?

...?
...?

...?
...?

...?
...?

...?
...?

...? minimize risks of measures Z

Xp2 5 S
...? ...? ...? ...? ...? ...?

S
(Xp)
Xpn 7
the outputs/ problems Y P
...?

...?

...?
...?

...?

...?
...?

...?

...?
...?

...?

...?
...?

...?

...?
...?

...?

...?
P

Operationalisation Graphical Display

Data-Collection-Plan
Problems
Y1
implement Implementation
(Y) Y2 operationalize influences xi, xm,
Yn qualify decide on measures
Xi1 xr and problems Y as measurands Y inform & Y
Input
Xi2 X motivate inform and motivate x
(Xi) determine scale level
Xin Z decide qualify (if necessary) Z
Process- Xp1
determine conditions and S S
Steps Xp2 implement measures
(Xp) Xpn procedure of measurement P P

Hypotheses Process-Capability Process-Control

Process-Capability/ -Control
C
Risk: 14%

There is a/ no Difference Process Capability Report for Yt1 _Cookie-Weight I-MR Chart of Y_Consumption_per_Day

in: the degree of: (Y) …

automatically generated with: LSL Target USL
Is the process mean stable?
Evaluate the % of out-of-control points.
Summary Report
Comments
The process mean may not be stable. 5 (15,6%) data points are out of control

Yield%/ DPU/ DPMO

o n t r o l

0% > 5% on the I chart. Keep in mind that you may see 0,7% out-of-control points by
Process Data Overall chance, even when the process is stable.
LSL 18 Within
Target 20 Yes No
Overall Capability

Y Y
USL 22 15,6%

- type of hypothesis
Sample Mean 20,9507 Z.Bench 0,1 8
Sample N 60 Z.LSL 1 ,26

between: Levels of (x)

Z.USL 0,45

Z.Bench (Sigma Level)/ cp/ cpk …

StDev(Overall) 2,3331 5
StDev(Within) 2,04775 Ppk 0,1 5
Cpm 0,26
Potential (Within) Capability Individual and Moving Range Charts

X X
Investigate any out-of-control points.
Z.Bench 0,31
25
Z.LSL 1 ,44 UCL=23,92

(Difference/ Relationship)
Z.USL 0,51
Individual Value

Cpk 0,1 7
10
_

I-MR/ xbar-R/ xbar-S/ P-/ U-Chart

X=5,89

Z -5

Z
- relevance of hypothesis (Risk)
LCL=-12,13

UCL=22,14
20
Moving Range

Test: ANOVA S Performance

1 5,0 1 6,5 1 8,0 1 9,5 21 ,0 22,5 24,0 25,5
10
__
MR=6,78

for the improved process S

- appropriate statistical tests
Observed Expected Overall Expected Within 0 LCL=0
PPM < LSL 1 00000,00 1 02992,26 74799,56

P P
1 4 7 10 13 16 19 22 25 28 31
PPM > USL 266666,67 326450,62 3041 79,60
PPM Total 366666,67 429442,89 378979,1 5 N: 32 Mean: 5,8947 StDev(within): 6,0087 StDev(overall): 4,0946

Control limits are estimated using the StDev(within).

Difference Relationship
Measurement-System-Analysis Boxplot of Y_Cookie_Weight Scatterplot of Y_Brightness_of_Cookie vs x_Baking_Time
Test Hypothesis
check repeatability, reproduci- 27,5 22

20
Difference-Hypothesis:
Y 25,0
Y
bility, stability and linearity of the X Ya =/≠ Yb
Y_Brightn ess_of_C ookie

18
Y_C ookie_W eight

22,5
16
X
Relationship-Hypothesis:
20,0

measurement system Z 1 7,5

14

12
Z
S S
Gage R&R P
1 5,0

t_1
time_of_measurement
t_2
10

10 12 14
x_Baking_Time
16 18 20 Y =/≠ f(x) P

12 011011102200801 Collect Data Plan Process

Monitoring and Out
Document
Project and present
Define Standards
for the new Process
Sustainability, Documentation
110114051978101 of Control Measures Results
Y Y
9 3 101501195801001 collect existing data X X
Start Continuous Continue checking Continue checking Process-Management-Plan
010100101010101 measure actual data Z Improvement (CIP) Target Achievement Process Capability Z
S Project-Story-Book S
001110100110011 according to Data-Collection-Plan
6 P P

Management (Sponsor, Accountable) Y Problem

Application S Solution sigmaGuide©
Belt (Black-Belt/ Green-Belt) Focus: X Influence/ Cause
P Tools: Copyright: reiner.hutwelker@sigmaLogic.de
& Support: Experts Z Effect
Project Management
Minitab©