Chapter 13

Six-Sigma Management and

Lean Tools

© 2001 Prentice-Hall Transparency 12-1

 Chapter Overview
If audio does not start
 What is Six-Sigma? on click, then hover over the
icon and click the play button.
 Organizing for Six-Sigma
 DMAIC
 Design of Experiments and the Taguchi
method
 Design for Six-Sigma
 Six-Sigma challenges
 postscript: Dilbert on Six Sigma

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 What is Six Sigma?
Slide 1 of 3

 Six Sigma () is where quality management

meets project management
 Coined by Motorola as core to their quality
improvement program
 Six refers to the number of SD’s from the
specialized limit to the mean.
 Six-Sigma aims to achieve very high capability
for competitively critical processes

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 What is Six Sigma?
Slide 2 of 3

Calculating 6 Sigma
• 6 sigma = process variation equal to half of design tolerance while
allowing mean to shift up to 1.5 standard deviations from target.

Assume: Sigma Long-term

Level ppm* defects
Specs are 10 +- 6
Sigma = 1 1 691,462
Sigma Shift = 1.5 (thus, assume process center at 11.5) 2 308,538

3 66,807
Solution:
Cp = (16 - 4) / (6*1) = 2.00  1 part per billion defectives 4 6,210

5 233
Cpk = min[ (16 - 11.5)/(3*1) OR (11.5 - 4)/(3*1)]
6 3.4
Cpk = min[ 1.50 OR 2.5 ]
Cpk = 1.50  3.4 parts per million defectives
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 What is Six Sigma?
Slide 3 of 3

Six-Sigma is … designed to handle the

most difficult quality problems.

% Quality
Techniques
Problems
90% Basic tools of Quality

< 10% Six-Sigma

< 1% Outside specialists

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 Organizing for Six Sigma

 Six Sigma follows project management stages

 Employs Interdisciplinary project teams
 The key players
 Champion. Work with black belts to identify possible
projects
 Master Black Belts. Work with and train new black belts
 Black Belts. Committed full time to completing cost-
reduction projects
 Green Belts. Trained in basic quality tools

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 Proceed to Lecture B

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