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Sudhakar SR
Objectives
Six
SixSigma
Sigma is
isaa Business
BusinessPhilosophy
Philosophy
History
Six
SixSigma
Sigma is
isaa Competitive
Competitive Tool
Tool
Expectations of People Capability
LEVEL CONTENT COMPETENCY
50,000 feet view Characterize & Everybody should
Optimize understand, use & teach
Applicable
Applicableat
atall
all levels
levels
The Standard Deviation
1 Sigma - 68%
= (X X) 2
2 Sigma - 95%
3 Sigma - 99.73 %
n-1
1
p(d)
1
0.27% Defects up-to 6.6 %
2
Customer
Target Specification
After
1
2 6 !
3 No Defects!
4
5
6
Y f (X)
Dependent X1 . . . XN
Output Independent
Effect Input-Process
Symptom Cause
Monitor Problem
Control
Would you control target or the shooter to get the Gold Medal?
The Eye of the Beholder
Customer
Process
A B C
Supplier Process
Focus
Focuson
onAverage
Averagecan
canturn
turnyour
yourbusiness
business
red
red
The Need for Six Sigma
iz
You have a problem
Defin
t er
Identify Project, People and definition and a thorough
Process e execution plan
ac
ar
HR Purchasing
6 Sigma
Methods
Finance Manufacturing
Software
Example - Pizza Delivery Service
SIPOC
Stratification Analysis
Contract Sheet
The 7 Basic Tools - 1
STRATIFICATION ANALYSIS:
Stratification analysis (Is / Is Not Matrix) is helpful in defining the
conditions surrounding the problem - bounding or scoping
Is Is Not Distinctions
West and North
South, East and West and North
Geography Delhi are sub-
Central Delhi Delhi
contracted
Mixups, Hygiene,
Output Delivery time
Temperature
Premium service
Lower and Middle
Customer Higher Income for higher
Income
income group
Increased
Time After Aug 09 Before Aug 09 employees in
Aug 09
The Define Phase - Summary
Loss (Deviation)2
Loss
VOC
Competitive Benchmarking
Target Y
The Measure Phase - Step 2
The customer
tolerance
window is 30
minutes on
LSL either side USL
Customer Customer
does not want does not want
earlier than This is the later than this
this target
delivery time
45 30 15 0 15 30 45
EARLY DELIVERY (MINUTES) LATE DELIVERY
Visualize
Visualizecustomer
customerrequirements
requirements
The Measure Phase - Step 2
Generate a list of Xs
Brainstorming
Process Map (PMAP)
Failure Modes Effects Analysis (FMEA)
Cause & Effect Diagram or Fishbone
Quality Function Deployment (QFD)
Prioritization Matrix
Check-sheet
The 7 Basic Tools - 2
CHECK-SHEET (DATA COLLECTION FORM)
Others l ll l 4
Prepare
Prepareto
tocollect
collectdata
data on
on the
theXs
Xsalso
also!!
The Measure Phase - Step 3
Learn more about the PMAP, FMEA and MSE in the Six Sigma
Green Belt Training.
The Analyze Phase - Step 1
HISTOGRAM
Target time Delivery time Target time Delivery time Target time Delivery time
hrs hrs hrs hrs hrs hrs
12:30 12:18 13:00 12:38 13:30 13:45
12:30 12:26 13:00 13:09 13:30 13:21
13:30 13:34 13:00 12:49 12:00 12:17
13:30 13:42 13:00 13:05 12:00 11:58
13:00 13:07 13:30 13:31 12:00 12:17
13:00 13:06 12:00 12:04 12:00 11:46
13:30 13:23 12:00 12:08 12:00 11:53
13:30 13:41 12:00 12:10 12:30 12:33
12:30 12:26 13:00 13:18 12:30 12:30
12:30 12:37 13:00 13:01 13:30 13:28
The 7 Basic Tools - 3
CREATING A HISTOGRAM:
Using the concept of the late and early deliveries, take the target
time as the reference, and find the number of minutes by which
each delivery is late or early.
45 30 15 0 15 30 45
EARLY DELIVERY (MINUTES) LATE DELIVERY
Measure
Measurethe
theprocess
process output
output
The Analyze Phase - Step 1
Customer tolerance
Z= Process standard deviation
LSL USL
30 minutes
Z= 10 minutes
Z=3
45 30 15 0 15 30 45
EARLY DELIVERY (MINUTES) LATE DELIVERY
Measure
Measurethe
theProcess
ProcessOutput
Output
The Analyze Phase - Step 1
Defects per
Process Million It is cost
Capability Opportunities effective to
2 308,537
Inspect in
Quality
3 66,807
4 6,210 Manufacture in
Quality
5 233
Design in
6 3.4 Quality
Higher
HigherZZ implies
implies lower
lower defects
defects
Getting the Competitive Edge
Sweet Fruit
Design for Processability
Bulk of Fruit
Process Characterization
and Optimization
Ground Fruit
Logic and Intuition
Sigma capability, Z
U.S. Manufacturing industry average 4.0
Six
SixSigma
Sigmais
isaaMetric
Metric
The Analyze Phase - Step 2
Center Reduc
Proces Target e
s Spread
Hypothesis testing
LSL USL
Understand
Understandyour
your Problem
Problem
Quiz - Characterize
Six Sigma is a What is the Y?
A. Statistical Quality Tool A. Measurable Process Output
B. Business Philosophy B. Voice of the Customer
C. U.S. Management style C. Process Input
The goal of Six Sigma is to Who gives the USL and LSL?
A. Reduce defects to 3.4 per million A. Management
B. Improve products B. Customer
C. Reduce variation C. Derived from the process data
In the Pizza Delivery Service example, In the example, the Voice of the
what is the CTQ? Customer is characterized by
A. Lunch A. Delivery time
B. Time B. No. of deliveries made
C. Delivery C. Tolerance around the Target
If a process is Six Sigma (Z=6), it implies In the example, the delivery service is
A. Process is 99.99% good characterized by
B. Products are 99.99% defect free A. Mean delivery time
C. There are only 3.4 defects in a million B. Tolerance around the Target
opportunities C. Mean & variation of the delivery time
The Analyze Phase - Step 3
Develop
Develop aalist
listof
ofXs
Xsthat
that possibly
possiblyaffect
affectYY
The Improve Phase - Step 1
To find the Vital Few Xs and separate it from the Trivial Many
Pareto
ANOVA (Analysis of Variance)
Regression
Chi-Square tests
Statistical
StatisticalAnalysis
Analysisto
toidentify
identifyVital
Vital Few
Few Xs
Xs
The 7 Basic Tools -5
PARETO
This is also called the Pareto Principle or the 80/20 rule and is used
to identify the Vital Few Xs.
Others
Location
Order Size
Parking
Traffic
Label
Regression
Scatter Diagram X2
X1
The 7 Basic Tools - 6
SCATTER DIAGRAM
A Scatter Diagram is a graph that shows the relationship between
two numerical variables, X and Y
In this example, the Scatter Diagram shows that the Delivery time is
less if the number of lunches per delivery person is less.
The Improve Phase - Step 3
y = f ( x)
USL
DELIVERY TIME
LSL
x
xL xT xU
NO. OF PIZZAS PER DELIVERY PERSON
The Control Phase - Step 1
LSL USL
Z = 4.5
45 30 15 0 15 30 45
EARLY DELIVERY (MINUTES) LATE DELIVERY
The Control Phase - Step 3
RUN CHART
A Run Chart is a time series plot of data that allows a team to study
observed data for trends or patterns over a specific period of time. It
captures instances when the process is changing more than
statistically expected
30
No. lunches/person
20
10
0
The DMAIC Steps and Deliverables
STEP DELIVERABLES
A. Identify project CTQs Identify customers, customer CTQs and Business Case
B. Develop Team Charter
C. Define Project Scope D
Problem statement, Project Scope,Team, Milestones
High Level Process Map connecting customers to process
A
3. Evaluate Measurement System Ensure measurement system is capable
I
5. Define performance objectives Understand statistical objective - reduce variation or shift means?
6. Identify sources of variation List significant causes (Xs) or factors
C
7. Screen potential causes Determine vital few Xs, which will be controlled
8.Discover variable relationship Find causal relationship and optimal solution
9. Establish operating tolerances Validate the relation and determine specs on Xs
Its
Itsaacommon
commonsense
senseapproach
approach
Attributes of a Six Sigma GB project
SIX SIGMA
ROLES & RESPONSIBILITIES
Roles and Responsibilities
Executive Champion
Responsible for providing resources to BB/GBs
Help in team selection
Track progress of project
Generally is supervisor of BB/GB. May help in selection of the project
Sponsor
Call for need of project (Project identification)
Beneficiary of the project
Validate current status and status after completion of project
Allocates resources for the project
Ensure compliance to controls established as a result of the project
Project Leader (Black Belt / Green Belt)
Lead the project
Ask for resources required
Call meeting of stakeholders and seek help from EC when stakeholders are
not responding
Ensure team involvement and sponsors buy in for solution
Publish weekly progress report & call for help when required
Roles and Responsibilities
Deployment Champion
Mentor and guide BBs/GBs
Provide technical help when BBs/GBs reach a roadblock
Publish Summary report of all projects
Raise alarm when things are not moving
MBB
Train BB/GB
Assess the skills of BB/GB
Certification of GBs and BBs after completion of projects
Deployment of Global policies and procedures
CFO/Finance
Assess the saving potential at start of project
Validate savings against the targets achieved at completion of project
Roles and Responsibilities
score of 5 or Technical
greater in all
Certification A
tool sets? Yes
10 weeks (3 - 5 day training) Based on demonstration of the Six
Sigma tools.
3 months avg. Occurs during project
No reviews and
on-site visits
Improve Tools and Instructor or MBB is
responsible
Application to Project
for technical certification.
Evaluation form sent to GB
and
Project Completed Champion after each session.
and Final Report
A Submitted and Six Sigma Green Belt and
Approved by
Yes I & CIM Associate Certification
Sponsor and
Finance
No