Professional Documents
Culture Documents
Six Sigma
Introduction
CM
6 Sigma
Six Sigma
Lean Definition
Future State
Why I am here...
Six Sigma
Business Strategy
Product Family
Identification
Lean System
Where I am...
Customers
Process & Information
Flow
Suppliers
Where I
want to be...
Future State Map
6 Sigma
TPM
SMED
Continuous Flow
Lean Tools
[When I know the solution]
Pull
Standardized Work
Poka-Yoke
Implementation
Plan
Constraint Management
When Im going
to get there
VSM
Six Sigma
Strategy Definition
Current State Map
Future State Map
Implementation Plan
Constraint Management
Kaizens
6 Sigma Tools
Lean Tools
4
Six Sigma
Institutions
OurFinancial
Customers
Large Manufacturers
Small Manufacturers
WHOS USING
IT?
Telecoms
Hospitals Large Cities
Our Competitors
Universities
Six Sigma
Six Sigma
Six Sigma
Costs decrease
Defects decrease
Cycle time decreases
Customer Satisfaction increases
7
Six Sigma
% Good
% Bad
DPMO
30.9%
69.1%
691,462
69.1%
30.9%
308,538
93.3%
6.7%
66,807
99.38%
0.62%
6,210
99.977%
0.023%
233
99.9997%
0.00034%
3.4
Six Sigma
6 Practical Meaning?
99%
99% Good
Good Four
Four Sigma
Sigma
99.99966%
99.99966% Good
Good Six
Six Sigma
Sigma
U.S.
U.S. Postal
Postal System
System
20,000
20,000 lost
lost articles
articles of
of mail/hour
mail/hour
U.S.
U.S. Postal
Postal System
System
Seven
Seven lost
lost articles
articles of
of mail/hour
mail/hour
Airline
Airline
Airline System
System
Airline System
System
Two
One shortshort- // long-landing/five
long-landing/five years
years
Two shortshort- // long-landings/day
long-landings/day One
Medical
Medical Profession
Profession
200,000
200,000 wrong
wrong drug
drug
prescriptions/year
prescriptions/year
Medical
Medical Profession
Profession
68
68 wrong
wrong drug
drug prescriptions/year
prescriptions/year
Long-Term Yield
Six Sigma
Six Sigma
Six Sigma
Six Sigma
Six Sigma
Six
Six Sigma
Sigma
14
Improvement Roadmap
Six Sigma
Objective
The 5-step
Six Sigma
Problem
Solving
Process
Phase
Phase1:
1:
Define
Define
Phase
Phase2:
2:
Measure
Measure
Phase
Phase3:
3:
Analyze
Analyze
Phase
Phase4:
4:
Improve
Improve
Phase
Phase5:
5:
Control
Control
How do we know?
15
Six Sigma
DEFINE
MEASURE
Practical
Practical Problem
Problem
Statistical
Statistical Problem
Problem
What are the X's?
y f ( x1 , x2 ,..., xn )
What is the relationship of the Xs?
Practical
Practical Solution
Solution
CONTROL
ANALYSE
Statistical
Statistical Solution
Solution
IMPROVE
16
Six Sigma
Define
Measure
Analyze
Improve
Control
VSM
Thought & Process Map
Cause & Effect Matrix
Potential Failure Mode Effects Analysis
Measurement Systems Analysis
Statistical Process Control
Components of Variation Study
Design of Experiments
Capability Study
Control Plans
17
Six Sigma
Clarify business
strategy and
customer input
Select projects:
VSM, strategy,
customers, etc.
Assign resources:
Champion, BB, GB,
other
Develop initial
Thought Map
Determine major
outputs: Big Ys of
the project (CTQs)
Define baseline,
and objectives for
key project metrics
Define Project
Charter and agree
on savings
Six Sigma
MEASURE
Develop Process
Map with inputs (xs)
and outputs (ys)
Develop Cause
and Effect Matrix
Update Thought
Map and revise
Project Charter
Complete FMEA for
key inputs (top xs)
Six Sigma
ANALYZE
Define major
effects: key inputs
outputs
Multi-Vari / COV
Understand effects:
Chi-Square,
ANOVA and
Regression
Develop Design of
Experiments plan
Conduct Design of
Experiments
DOE
Define relationships
between inputs and
outputs y=f(x)
Define how to
eliminate / reduce
output variation (ys)
Conduct
confirmation studies
and DOEs
Define improvement
opportunities and
update Thought
Map
Six Sigma
IMPROVE
Implement process
improvements for
critical xs and ys
Continue to learn
about y=f(x) and
update Thought
Map
Conduct DOE
optimization studies
(Response
Surface)
Update Process
Map, MSA, FMEA
and Control Plan
Document / monitor
improvements
SPC / Capability
Define follow-up
actions and
responsibilities
Define financial
impact of
improvements
Update Project
Charter
21
Six Sigma
CONTROL
Define control
methods for critical
xs / ys: Control
Plan
Finalize Process
Map and FMEA
Establish / review
Quality System
procedures
Establish process
control for critical
xs / ys: SPC
Ensure capable
measurement
systems: MSA
Document product /
process changes
Finalize financial
benefits with
Controller
Update Project
Tracking and Cost
Out
Six Sigma
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