Doing The Right Things Right the First Time On Time and Every time Always Meeting Customers

Needs On a Continuous Basis

Conventional Products and Services that are provided exactly to Specifications. New: Products & Services that totally satisfy our customer needs and expectations in every respect on a continuous Basis.

Six Sigma is not Eureka It gradually evolved over time.

The Pioneers/major contributors to the same was Motorolla since 1979 Bill Smith.

Financial Institutions IT Market Space Customer Service Aviation Hospitals Educational Institutes and so on..

Sigma is : Measurement The sigma value is a metric that indicates how well the process is performing. The standard of excellence (3.4 defects per million opportunities)

DMAIC : Define Measure Analyze Improve Control meant for Existing processes.

DMADV : Design, Measure, Analyze, Define, Validate

Internal Customers

External Customers

Improvement teams use the DMAIC methodology to root out and eliminate the causes of defects: Define a problem or improvement opportunity. Measure process performance. Analyze the process to determine the root causes of poor performance; determine whether the process can be improved or should be redesigned. Improve the process by attacking root causes. Control the improved process to hold the gains.

1.Define: You will define the goals of the project and that of the customers (both internal and external) 2.Measure: Here you will quantify the customer needs as well as the goals of the management 3.Analyze: Analyze the options, existing process to determine the cause of error origination and evaluate corrective measures 4.Design: Design a new process or a corrective step to the existing one to eliminate the error origination that meets the target specification 5.Verify: Verify, by simulation or otherwise, the performance of thus developed design and its ability to meet the target needs

20,000 lost articles of mail per hour. Unsafe Drinking water almost 15 minutes per day. 5000 Incorrect Surgical Operations per week. 2 Short or Long Landing at most Major Airports each day. 200000 wrong drug prescriptions each year No Electricity for almost 7 Hours per month.

VOC Voice of customer, Captured through means like Focus Groups, Complaint cards, Feedback forms. Understanding Critical to quality factors: The attributes of Customer requirements which are critical, measurable, quantifiable and specific.

QFD Quality Function Deployment or House of Quality is a tool that transforms the VOC into the ultimate product/service design.

The Goals/Objectives of the improvement Project must be aligned to the Organizational Goals. Milestones/Deliverables must be stated in the project charter.

LSL Lower Specification Limits USL Upper Specification Limits Deviation/Variation : The extent to which a process variates from the centre (mean) STD Deviation A Measure to determine dispersion of Data values from the mean.

Defect Rate = no of defects/total nos.

CTQ : 3
Defect Rate/CTQ

Defects Per Million Opportunity = 1000000 * Defect Rate/CTQ

Look up the Global sigma value tables to determine the Sigma values.

Define simplified QFD Get input on detailed needs of project from inspectors, line maintenance, quality engineers, design engineers, production manager, and customers. Develop action list. simplified FMEA Identify any other processes that may be negatively affected by implementing this project. (For example, the extra time required of line maintenance people may negatively affect the maintenance of other equipment.) Develop action list. fishbone diagram Identify all the input variables causing the diameter to vary, to make sure we have samples of all types of diameter variations. This enables us to verify that all variations of diameters can be measured using the laser and digital camera device.

Measure calculate minimum sample size, variables data Determine the number of sample products required to run statistically valid tests on the new equipment.

Analyze test for significant change, variables data (decimals) two-sample test Run tests on the sample products using both the traditional manual dial indicator measurement method and the test setup. Verify that there is no significant difference between the two methods. If a difference is found, additional tests will be required to identify the reason(s).

Improve test for significant change, variables data (decimals) two-sample test Run tests on the product samples using both the traditional manual measurement method and the production device. Verify that there is no significant difference between the two methods. If a difference is found, additional tests will be required to identify the reason(s).

Control test for significant change, variables data (decimals) population/sample Using the output data, continuously calculate results on a running sample and compare the results with historical data. If the running sample results are statistically different from the historical population results, then the device may not be working properly. Line maintenance would then be alerted. simplified control charts Using the measurement output of the new device, implement a simplified control chart to help the operator reduce diameter excursions.

SIPOC Diagrams Fish Bone Analysis QFD Run/Control Charts Hypothesis Testing FMEA

Check Sheets Pareto Charts Cause n Effect Diagrams Histograms Scatter Diagrams Flow charts Control Charts

Quality is subjective- changes over time Kano Analysis Demand Management An ideal continuous process is always circular PDCA & PDSA

Lets Look at a Practical Project to gain better understanding