How to introduce SIX SIGMA

Six Sigma Introduction

six sigma model

lean-six-sigma

What is six sigma?

Sigma ( s ) is Greek letter used to indicate standard deviation

– A sigma level provides a statistical estimation of the the defect (error) rate

– Six sigma relates to 3.4 Defects Per Million Opportunities (DPMO)

2 ways of implementing six sigma

– As a management philosophy, e.g. General Electric

– As a quality tool for problem solving , most of companies are using it in this way

Six Sigma Origins

In 80s, a Motorola engineer found that less than 5% of the products reached the final station without any repair with a big impact on productivity & repair costs

The engineers decided that the traditional way of measuring defect rate (%) is not satisfying, instead to measure defects per million opportunities

Motorola developed this new concept and created the methodology, which named Six Sigma

– As a continuous improvement tools

The results for MOTOROLA up till 2003

Spent $70 million on quality related education

In 1988, won Malcolm Baldrige (the USA quality award)

Productivity increased average of 12% /yr

Cost of quality reduced by more than 84%

99.7% of in-process defects eliminated

$16 billion in manufacturing costs saved

General Electric Six Sigma Deployment

Capacity improvement of 12-18%

Rise in operating margin to 16.7%

$750 million in saving

 

GE Capital Mortgage Insurance

Cut defects 96%

Claim payments were reduced by $8M, while borrowers were offered alternatives to foreclosure

Reported a 160% increase in new transactions

Normal Distribution Curve

Normal Distribution Curve

why6s1

Accuracy & Precision

Accuracy & Precision

600532-dmm-accuracy_715x360-01

What’s the difference between accuracy and precision?

 

Why 3.4 DPMO ( Defect Per Million Opportunity) ?

 

 why6s2

Measured process may shift by much as 1.5 sigma, resulting in a max DPMO of 3.4

Six Sigma scale

Six Sigma scale

6sigma-scale

 

Harvesting the fruits of 6 s

Harvesting the fruits of 6 s

six-sigma-fruites

The Six Sigma DMAIC Model

Define

  • Define and scope the project (including deliverables)
  • Define an acceptable project schedule
  • Achieve consensus on project definition

Measure

  • Process definition
  • Metric Definition
  • Measure process baseline
  • Evaluate Measurement System

Analysis

  • Analyze value stream
  • Analyze source of variation
  • Determine process drivers

Improve

  • Generate improvement ideas
  • Prioritize improvement opportunities
  • Define new process flow
  • Define & mitigate failure modes
  • Define new process factor levels

Control

  • Maintain improvement
  • Measure realized bottom-line impact
  • Apply the knowledge elsewhere

The Six Sigma Tool Box

SPC/ Engineering process control/ Operational procedures/ control plans/ Training/ Audit

Improve

Brainstorming/ Affinity/ Mind mapping/ Benchmark/ FMEA/ DOE/ Six thinking hats technique/ Root cause analysis/ Process decision program chart /

Analysis

Scatter diagram/ Regression model/ Anova/ Multiple regression/ DOE/ Lean methods/ Value / tream analysis/ Process cycle efficiency/ 5 S/ Setup reduction

Measure

Flowcharts/ Process Maps/ SIPOC / Box-Whisker plots / Cause & effect diagram/ Check sheets

Interrelation digraph/Pareto diagram/ Stem & leaf plot/ Gage R&R/ SPC control charts

Histogram/ Process capability

Define

Matrix diagrams/ Work breakdown structure/ Pareto diagram/ Process maps/ Financial analysis

Affinity diagram/ Nominal group technique/ Prioritization matrix/ Project scheduling

Activity network diagram/ Pert analysis/ Gantt chart/ Quality function deployment

How to apply six sigma (general concept)?

6sigma-implementation

 

case study (call center)

Simple excel sheet for Gage RR

 

Comments

  1. Nice post. Thank you!

  2. Nice post. Thank you!

  3. Years ago it was less complex to be liked by online search engine, basically
    you had to understand exactly how a website needed to be built, as well as how to optimize it for your key
    words, positioning the key phrases in the title of the page, in the meta tags and also in the body
    of the page, focusing on the thickness of the keyword phrases in the entire record.

  4. Years ago it was less complex to be suched as
    by internet search engine, essentially you needed to understand exactly how a website needed to be created,
    as well as the best ways to optimize it for your key phrases, putting the keywords in the title of the page, in the meta tags and in the body of the page,
    taking note of the thickness of the keyword phrases in the whole paper.

  5. Nice post. Thank you!

  6. Even even worse, if your resume doesn’t list anything below your name and just
    studies experience then you are missing out on a vital element of being indexed by these internet search engine.

  7. Nice post. Thank you!

  8. Dr. Oz is one of the many scientists who stands behind Garcinia Cambogia Extract.

  9. Nice post. Thank you!

  10. Nice post. Thank you!

  11. Remember that the ranking will establish your location in the internet search engine results
    web page (SERP) – a page that returns a checklist of results ranked
    according to a number of elements.

  12. Nice post. Keep it up.

  13. Nice post. I learn something more challenging on different blogs everyday. It will always be stimulating to read content from other writers and practice a little something from their store. I’d prefer to use some with the content on my blog whether you don’t mind. Natually I’ll give you a link on your web blog. Thanks for sharing.

  14. Nice!

Speak Your Mind

*