A short introduction Hans van Veen May 2013.
4.6 sigma means
● 4000 newborns accidently being dropped after birth per year
● 2 highly problematic landings each day on US airports
● 400 lost letters per hour at US-Post
6 sigma means
● 10 newborns accidently being dropped after birth per year
● 2 problematic landings each year on US airports.
● 1 lost letter per hour at US-Post● Watch off by 2 seconds in 31
years
Some other data
● Restaurant bills, doctors prescription writing, and payroll processing – 2.9 σ
● Average company – 3.0 σ● Airline baggage handling – 3.2 σ● Best in class companies – 5.7 σ● U.S. Navy aircraft accidents – 5.7 σ● Airline industry fatality rate – 6.2 σ
As a Methodology
● Consistent use of DMAIC-Models.● Team based problem solving.● Mesurement based Process Analysis,
Improvement and Control.
As a Management System
● Six Sigma drives strategy execution.● Leasdership, sponsorship and review.● Metrics driven governance process.● Engagement across the organization.
Design of ExperimentsSpot welding schedule set up with a 3³ design.
● 3 levels for electrode pressure
● 3 levels for current
● 3 levels for time
Optimal combination is somewhere in the cube and can be found easily with dedicated software (Minitab, SAS, SPSS, Cornerstone, R-DoE.ResultTrial & Error ==> DoE:3 days ==> 4 hours.
Problem Solving
Sieve deck lifetime was 5 weeks.● Ishikawa diagram (Fishbone)● FMEA● Choise of best possible solution (Adhesive)● Experimental sieve deck manufactured● New deck followed and measured regularly
New lifetime ==> 8 months.
Yearly savings ==> 150 k€
Much more important ==> Process stabilisation