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Pramod Naim Alok: Basics
Pramod Naim Alok: Basics
BASICS
Naim DMAIC
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DFSS
Alok ●
SIX SIGMA BELTS
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EXAMPLES
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GE
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DABBAWALAS
What is six sigma?
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• A “defect” is any mistake that results in customer
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dissatisfaction.
• The higher the sigma level, the lower the defect rate.
1818: Gauss uses the normal curve 1924: Walter A. Shewhart introduces
to explore the mathematics of error the control chart and the distinction of
analysis for measurement, probability special vs. common cause variation as
analysis, and hypothesis testing. contributors to process problems.
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• Also, it provides a common basis for benchmarking
(competitors and non-competitors).
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• The higher the sigma level, the better your operation
is performing.
ᵟ
(Distribution Shifted ± 1.5)
PPM
PPM
2
2 308,537
308,537
3
3 66,807
66,807
4
4 6,210
6,210
5
5 233
233
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6 3.4
3.4
Process
Process Defects
Defectsper
perMillion
Million
Capability
Capability Opportunities
Opportunities
Possible applications
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•Customer Service: measure the number of calls answered
on the first ring.
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•Order Fulfillment: eliminate Customer returns because of
incorrect parts or product being shipped.
2.Measure key aspects of the current process and collect relevant data.
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3.Analyze the data to verify cause-and-effect relationships. Determine what
the relationships are, and attempt to ensure that all factors have been
considered.
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4.Improve or optimize the process based upon data analysis using various
tools
5.Control to ensure that any deviations from target are corrected before
they result in defects.
Tools used for dmaic
approach
define
measure
1. Stakeholders analysis
2. Surveys 1.FMEA
3. CTQ’s Improve 2.Pareto analysis
4. Benchmarking 3.Data collection
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4.PDSA cycle
5. Run charts
Brainstormin
g
Force Field
Analysis Analysis
(PDSA) Cycle Control
Cause and Effect Chart Team
FMEA
Brainstorming Performance
Control Plans
Histogram Improvement
Plan, Do, Study,
Pareto analysis
Act (PDSA) Cycle
Scatter Plot
Plan
Regression Analysis
Team
FMEA analysis
Performance
Improvement
DMADV APPROACH
Define design goals that are consistent with customer demands and the
enterprise strategy.
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Measure and identify CTQs (characteristics that are Critical To
Quality), product capabilities, production process capability, and risks.
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Analyze to develop and design alternatives, create a high-level design
and evaluate design capability to select the best design.
Design details, optimize the design, and plan for design verification.
This phase may require simulations.
Verify the design, set up pilot runs, implement the production process
and hand it over to the process owners.
DMADV is also known as DFSS, an abbreviation of "Design For Six
Sigma".
DMAIC DMADV
.
1.Define
customer needs
1.Defines a 2.Measure
business process customer needs
& specifications
2.Measuring
current process 3.Analyze options
to meet customer
V/S
3.Identify root satisfaction
cause of the
recurring problem 4.Model is
designed to meet
4.Improvements customer needs
made to reduce
defects 5.Model put
through
5. Keep check on simulation tests
future for verification
performance
The six sigma organization.
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time of implementation of a project.
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There are four “Belt” levels :-
1. Champion
2. Master black belt(MBB)
3. Black belt(BB)
4. Green belt(GB)
5. Yellow belt(YB)
Champion
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•Approves six sigma projects
•Removes road blocks in the path of six sigma
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implementation
•Receives presentations
•Monitors project
•Make available necessary resources
•Sort out conflicts
Master black belts
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All duties involve implementation of Six
Sigma,
strategic
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including
and
statistical
policy
analysis,
planning and
implementation, and training and mentoring
of Black Belts.
Black belts
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methods;
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all job duties include implementation of Six
Sigma methodology throughout all levels of the
business,
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a Six Sigma-trained professional who does
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not work on Six Sigma projects exclusively,
but whose duties include leading projects
and teams and implementing Six Sigma
methodology at the project level
Yellow belt
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applies to a professional who has a basic working
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knowledge and who may manage smaller process
improvement projects,
• Variability is necessary.
• Total variability is the result of two types of
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causes : chance causes and assignable causes .
chance causes cant be identified and hence can
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not b e eliminated while assignable causes can
be identified and immediately eliminated.
• Process means in real life can shift from the
nominal mean by 1.5 times of standard
deviation.
• Defects are randomly distributed throughout
the units, and parts and processes are
individual.
Continue…….
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specified for the output and some variations are allowed
from the ideal measure.
These requirements are usually stated in terms of
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USL=upper specification limit
LSL=lower specification limit
Defects are randomly distributed throughout the units
and parts and processes are individual. since measured
values follow a normal distribution with mean and
standard deviation, the process capability of the process
will be equal to mean.
Continue………….
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nominal by 1.5 times the standard deviation
due to gradual drift or as a result of sudden
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drift, defects rates in practice expected at a
different sigma levels are higher than in the
mean centered process.
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variation (standard deviation).
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• Increasing the design width.
Defects in six sigma.
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exciting
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• Detraction from creativity
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1998 Operating margin—16.7%