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Six s
Sigma is a letter in the Greek alphabets The term Sigma is used to denote distribution or spread around the mean (average) of any process or procedure For a business or manufacturing process, the sigma value is a metric that denotes how well the process is performing The higher the sigma value the better. The sigma value measures the capability of the process to deliver defect free output A defect is anything that results in customer dissatisfaction With Six Sigma the common measurement index is defects per unit where a unit could be anything--a component, piece of material, time frame, distance etc. The higher the sigma value, the less likely a process will produce defects. As sigma value goes up, customer satisfaction naturally goes up. Six s
What is Sigma?
Sigma is a statistical measure (Standard Deviation) denoting level of defects in a process/parameter It is a means to denote variation in a process
Examples of Control limits and Std Dev.
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Day 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Process 1 49.4 47.7 49.2 49.1 49.9 48.6 47.9 53.2 48.9 48.1 51.0 50.1 54.3 49.4 52.2 45.5 56.8 55.1 48.2 50.2
Process 2 43.8 51.2 47.6 46.6 57.0 53.3 59.6 46.8 55.4 40.3 60.2 46.2 54.7 51.1 57.5 54.1 53.6 49.0 55.6 45.0
Specs
35
35 38 41 44 47 50 53 56 59
Specs
56 59 62 65
62 65
38
41
44
47
50
53
1 1 3 5 7 9 11 13 15 17 19 21 3 5 7 9 11 13 15 17 19 21 23
Days
23 25 27 29 31 33 35 37
Process 1
Process 2
Days
25 27 29 31 33 35 37 39 41 43 45 47 49
39 41 43 45 47 49
Customer requires Target value50 and range from 40 to 60. Which process has the capability to meet customer requirements?
Process 1 : Mean is 49.8 Std Deviation is 2.53, Ranging from 56.8 to 42.8 Process 2 : mean is 49.8 Std Deviation is 4.39, Ranging from 60.2 to 38.9
Specs
No of Days
Counts 1 2 3 10 12 22 20 17 8 3 2
Histogram of Y
Normal 25
Mean 99.67 StDev 10.02 N 100
20
Frequency
15
10
80
90
100 Y
110
120
130
34.13%
34.13%
0.13%
2.14%
-3
13.06%
2.14%
0.13%
-2
+2
+3
95.46%
99.73%
In the chart below, 64.6% of the measures are between the upper and lower limits
Lower Limit Upper Limit
34.13 %
34.13 %
This is a 1 s process Reducing the variations in the process will bring a higher percentage within the acceptable limits
Time Intervals
Time Intervals
W I D E Variation
Slim Variation
Target
Target
Time (Min.).
Time (Min.).
ZERO DEFECTS
Control Chart
Abnormal variation due to assignable sources Out of control
UCL
Mean Normal variation due to chance Abnormal variation due to assignable sources
LCL
10 11 12 13 14 15
Sample number
Tracking Improvements
UCL UCL UCL
LCL LCL Process centered Process not centered and stable and not stable
LCL
Customer
Anyone internal or external to the organisation who comes in contact with my work, product or service Anyone whose satisfaction depends on my output and actions
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4s
6s
Current best
New with 6 s
6,210
3.4
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What is Six Sigma? Not only a statistical tool but, An attitude which continuously and relentlessly strives to achieve an almost zero defect level in any process. It is this attitude which gives maximum results in the longer run. It also makes the organisation robust
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Why Six Sigma? A structured tool/methodology to reduce and thereafter control defects in any process Reducing defects translates to
Better understanding of customer requirements Better customer satisfaction Increased customer loyalty Increased revenues Reduction in costs
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Y=f ( X, X1Xn)
Y
Dependent Output Effect Symptom Monitor
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X
Independent Input/Process Cause Problem Control
Capability=f(Variation)
$
Customer Satisfaction
Yield Improvement
Defect Reduction
The Role of Measurement If we cannot express what we know in the form of numbers then we do not know much about it If we do not know much about it then we cannot control it If we cannot control it then we are at the mercy of chance
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Improve
Optimisation Control
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Measure
Capability OK?
Analyse
Modify Design?
Improve
Capability OK?
Control
Redesign
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1 Select CTQ Characteristic 2 Define Performance Standards 3 Validate Measurement System 4 Establish Product Capability 5 Define Performance Objectives 6 Identify Variation Sources 7 Screen Potential Causes 8 Discover Variable Relationships 9 Establish Operating Tolerances 10 Validate Measurement System 11 Determine Process Capability 12 Establish Controls
How is Six Sigma implemented in an organisation? Total commitment and trust from the management is a key to success Champions for critical business areas Dedicated Black Belts for each project Process Owners to define a project and its charter
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How is Six Sigma implemented in an organisation? (Continued) Business Area examples, Manufacturing
Production, Maintenance, Electrical systems etc.
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In effect they should be those employees whose absence will be felt in their departments
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S.M. Pathak
Six Sigma : Project stages Measure Data collection and evaluation of current Process Capabilities (sigma levels) Preparation of Process Flow Input and Output variables Failure Modes and Effects Analysis (FMEA)
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Six Sigma : Project stages Analyse Statistical analysis and correlation of parameters Root Cause Analysis Analysis of Behaviour (ABC and BOC) Identify parameters for improvement
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Six Sigma : Project stages Improve Design of Experiments (DOE) based on Analyse phase Analyse data from experiments Draw conclusions
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Six Sigma : Project stages Control Prepare plan to Manage Change Prepare modified Process Flow Prepare a control plan document Pin point responsibilities for the change Identify process owners for control purposes
Any Questions???
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