Six Sigma (6)

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History of Six Sigma (6)

In 1986 Bill smith, Seniors Engineer and
scientist introduces concept of Six Sigma
Bill smith Known as Father of Six Sigma
In 1995, Jack Welch introduced Six Sigma
at GE

Whats in a name?
Sigma is the Greek letter representing
the standard deviation of a population
of data.
Sigma is a measure
of variation
(the data spread)

What is Six Sigma ?

A
philosophy?

What is
Six
Sigma?
A metric?

A
methodology?

What is Lean Six Sigma?

What is Lean ?
Goal Eliminate waste and increase process
speed
Method
Genchi Genbutsu Go and See the workplace
(Gemba)
Kaizen (Change for better) workshops

What is Lean Six Sigma ?

What is Six
Sigma ?
Goal Reduce variation to improve performance on
CTQs
(Variation means system does not produce
same result each time)
Method DMAIC, DMADV,DFSS approach

Normal Distribution Curve

Lower
Spec

Upper
Spec

- 1

+ 1

68.26%
- 2

+ 2
95.44%
+ 3

- 3
- 4
- 5
- 6

99.73%
99.9937%

+ 4
+ 5
+ 6

99.999998%
99.99943%

Sigma

%
Good

1
2
3
4
5

30.9%

69.1%

691,462

69.1%

30.9%

308,538

93.3%

6.7%

66,807

99.38%

0.62%

6,210

% Bad DPMO

99.977 0.023%
%
99.9997 0.00034

233
3.4

What is Six Sigma performance?

USL

LSL

Your process is performing at sigma level of six if

Mean
the difference between mean and specification limit
is six times the standard deviation

? times

-6

-5 -4 -3 -2 -1

1
+1

Question - How many times of standard

deviation () is specification limit to
mean?
Answer Same as sigma level for the
process (Z value)

+2 +3 +4 +5 +6

Data Driven Approach

Y= f (X)
To get results, should we focus our behavior on the Y or X ?

Y
Dependent
Output
Effect
Symptom
Monitor
Response

X1 . . . XN
Independent
Input
Cause
Problem
Control
Factor

Is it feasible to eliminate the inspection of Y, if Xs are controlled well?

How Six Sigma Process

Follows?
Identify customer issues which generally follows timely
delay, high cost, defect etc
Internalized as performance measures such as
e.g. Cycle time, defect rate etc.
Target performance levels are established and then
company seek to perform around this targets with
minimal variation

THE DMAIC METHOD

5

CONTROL

DEFINE

4
IMPROVE

2
MEASURE

3
ANALYZE

Phase 1: Define
Projects Identification Method
VOC ANALYSIS
(Problem
identification
based on
customers
voice)
VOB ANALYSIS
(Problem
identification
based on
Business
COPQ
(Problem
problems)
identification
based on cost of
poor quality
i.e. Process
Defects )

Identification
of
CTQs

List of
problems/projec
ts of
organization on
the basis of
Criticality, Out
come , Time line

Phase 2: Measure

Goal
Focus the
improvement effort
by gathering
information on the
current situation
Output
Data that pinpoints
problem location or
occurrence
Baseline data on
current process
sigma
A more focused
problem statement

CONTROL

DEFINE

4
IMPROVE

e
Baselin
Data

2
MEASURE

Sampling
Gage

3
ANALYZE

Pat
t

Ca
p

ab

R&R

ern
s

ili
ty

DATA COLLECTION

The system to collect information is already established.

Find the data which supports the defined problem

Find out the data stream wise/ product wise etc..

Data type:

Attribute data or Discreet : Value of countable quality

characteristics
Example - Number of Defects, Number of Defectives.

Continuous data or Variable data : Value of measurable

quality characteristics
Examples - Strength (kg/cm2), weight (kg) , length (cm),
temperature ( C), time (sec)

Phase 3: Analyze
5

CONTROL

DEFINE

4
IMPROVE

2
MEASURE

3
ANALYZE

Goal
Identify deep
root causes and
confirm them
with data

Output

s
es
oc sis
Pr aly
An
ri
ti-Va
Mul

Organize
Causes

Hypoth
e
Testing sis

Re

gre
s
s
ion

Do
E

A theory that has

been tested and
confirmed

Phase 4: Improve
Goal
Develop, pilot, and
implement
solutions that
address root
causes.

Output
Identification of
planned, tested
actions that should
eliminate or
reduce the impact
of the identified
root causes

5
CONTROL
Solutions

FMEA
Pilo

4
IMPROVE

en
em n
pl tio
Im ta

DEFINE
2
MEASURE

3
ANALYZE

Solutions
Improvement team created with members of
Quality, Production, Engineering and R&D areas to
propose and evaluate ideas.
Brainstorming tool was used to gather ideas on
how to solve the problems identified.
Ideas were evaluated per following criteria:
feasible, high impact, easy, low cost, and quick.
Following tables summarizes solutions agreed by
consensus of the improvement team.

tr
Con
ol

e
iz

en
t

Ev
al
ua
te
Mo
ni
to
r
Clos
ure

rd
da

um
oc
D

Goal
Use data to evaluate both the
solutions and the plans
Validate that all changes
adhere to all operating
company change control, and
compliance requirements
Maintain the gains by
standardizing processes
Outline next steps for on-going
improvement
Output
Before-and-After analysis
Monitoring system
Completed documentation of
results, learning, and
recommendations

an
St

Phase 5: Control

CONTROL

DEFINE

4
IMPROVE

2
MEASURE

3
ANALYZE

Q.C STORY BOARD

Q.C Story board is representation of
all steps taken from identification to
solution and reviewable of taken
probable solutions
Clear problem identification is the
most imp part of Q.C Story Board
Different dept people needs to be
involved in a whole process to have
fresh ideas

PARETO ANALYSIS
Known as 80-20 Rule
Used for identification of Major
problems
To find out 20% problems which
causes 80% rejection

PARETO ANALYSIS
P
e
r
c
e
n
t
a
g
e

Code of defect

FISHBONE DIAGRAM

5 WHY ANALYSIS

5 WHY ANALYSIS

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