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Six Sigma Introduction.ppt

Jul 06, 2018

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    1

    Six Sigma

    IntroductionIntroduction

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    Lean Definition

      C M

     L  e an

    Current State Future State

    The Lean System crossing 

    Value Stream Map

      6  S i   gm a

     A strategy for achieving Continual Improvement in performance

    through the Enhancement of VALUE  in all resources and timeinvested throughout the total business process.

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    Lean System

    When I’m going

    to get there

    Where I

    !ant to "e###

    Where I am###

    Why I am here###

    $roduct Family

    Identification

    %usiness Strategy

    Current State Map Future State Map

    Implementation

    $lan

    Lean &ools!"hen I #no$ the solution%

    6 Sigma!"hen I don&t have the solution%

    Constraint Management!Control $hile I&m Improving%

    $rocess ' Information

    Flo!

    Customers

    Suppliers

    (S

    & $ M

    S M ) D

    Continuous Flo!

    $ull

    Standardi*ed Wor+

    $o+a,-o+e

    .o! I’m going to get there###

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    ''

    What /re &he Steps

    Strategy Definition

    Current State Map

    Constraint Management

    Lean &ools

    Future State Map

    6 Sigma &ools

    Implementation $lan   V   S

       M

       V   S

       M

    0ai*ens0ai*ens

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    ((

    What is the 1Six Sigma2 Concept3

    ) *eveloped at +otorola in the 1,-&s) Uses facts /or data0 and statistics

    ) ocused on problem solving

    ) elps drive defects to near 34ero& and reduce $aste

    ) Can be used in all departments

    ) 5ot 6another 7uality 8rogram9

    W.4’S 5SI7

    I&3

     A TOOL TO DRIVE BUSINESS RESULTS 

    Financial InstitutionsFinancial Institutions

    Small ManufacturersSmall Manufacturers

    .ospitals

    .ospitals

    Large ManufacturersLarge Manufacturers

    Large CitiesLarge Cities

    5ni8ersities5ni8ersities

    &elecoms&elecoms

    4ur Competitors4ur Competitors

    4ur Customers4ur Customers

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    ::

    What is Six Sigma3

    ;i< sigma is the fastest gro$ing business management system inindustry today.

    Centred on a po$erful problem solving and process optimisationmethodology.

    =he main thrust of si< sigma is the application of statistical tools in thecontedisciplined? easy to follo$ methodology.

    ;i< sigma is a defect reduction methodology. It uses Define9Define9Measure9 /nalyse9 Impro8eMeasure9 /nalyse9 Impro8e and Controland Control tools to reduce variation @improve areas of the business.

    +ost companies have bet$een ( and ( defects per millionoperations? or about sigma.

    =he goal is to reduce defects to the point $here errors $ould be

    almost non e

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    BB

    Six Sigma

    ree# letter D loo#s li#e this 6 σ 9

     A 3sigma level& measures the process[its ability to generate no defects] 

    =he higher the sigma level the better [the less likelihood a defect will occur] 

     As the sigma level of a process increases

     D Costs decrease

     D *efects decrease

     D Cycle time decreases

     D Customer ;atisfaction increases

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    --

    .o! Does 6 

    Measure

    Sigma : 7ood : %ad D$M4

    ;; : 6>#;: 6>;9?6@

    @@ 6>#;: : BB: =#=@#>>>B: =#===

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    ,,

    $ractical Meaning3

     Long-Term Yield 

    >>: 7ood Four Sigma

    5#S# $ostal System

    2? lost articles of mailhour 

    /irline System

    =$o short> long>landingsday

    Medical $rofession

    2? $rong drug

    prescriptionsyear 

    >>: 7ood Four Sigma

    5#S# $ostal System

    2? lost articles of mailhour 

    /irline System

    =$o short> long>landingsday

    Medical $rofession

    2? $rong drug

    prescriptionsyear 

    >>#>>>66: 7ood Six Sigma

    5#S# $ostal System

    ;even lost articles of mailhour 

    /irline System

    Fne short> long>landingfive years

    Medical $rofession

    :- $rong drug prescriptionsyear 

    >>#>>>66: 7ood Six Sigma

    5#S# $ostal System

    ;even lost articles of mailhour 

    /irline System

    Fne short> long>landingfive years

    Medical $rofession

    :- $rong drug prescriptionsyear 

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    11

    &he Focus of Six Sigma###

     - fEx;9 x

    @9 x

    <9 x

    ? x

    n

    G4utput’ is a function of a num"er of Ginputs’#

    7ood Carrot ca+e a function of Eflour9 carrots9 recipe9 sugar97ood Carrot ca+e a function of Eflour9 carrots9 recipe9 sugar9

    cinnamon9 eggs9 frosting9 oil9 "a+ing soda9 heat9 Gto last item’cinnamon9 eggs9 frosting9 oil9 "a+ing soda9 heat9 Gto last item’

    In other !ords G7ar"age in yields gar"age out’

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    1111

    $remise for Six Sigma Methods

     A 3defect& is process output outside ofcustomer e

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    1212

    Measurements /re Critical ###

    If $e can&t accurately

    measure something?

    $e really don&t #no$

    much about it. If $e don&t #no$ much

    about it? $e can&t

    control it.

    If $e can&t control it? $e

    are at the mercy of

    chance.

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    1

    Six Sigma 4"Hecti8es

    ) aining process #no$ledge

    )  Achieving continuous process improvement

    ) +a#ing fact>based decisions

    )  Applying the right tools to achieve business obHectives

    ) +a#ing positive behavioral changes

    7etting eal %usiness esults

    Customer Satisfaction

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    1'

    Six Sigma Comparison

    ;i< ;igma;i< ;igma  =raditional=raditional

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    1(1(

    Impro8ement oadmap4"Hecti8e

    *efine the problemWhat is the Gpro"lem’3

    .o! do !e +no!3

    What’s causing it3

    .o! can it "e impro8ed3

    .o! do !e G+eep it on trac+’3

    &he (,step

    Six Sigma

    $ro"lem

    Sol8ing

    $rocess

    =a#e measurements @ verify accuracy

    Identify the critical fe$ factors $hich

    directly influence the problem

    *etermine $ays to improve the results

    D

    M/

    I

    C+a#e sure the problem does not

    re>occur by controlling the fe$ factors

    $hase ;J

    Define

    $hase ;J

    Define

    $hase @J

    Measure

    $hase @J

    Measure

    $hase

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    1:1:

    emem"er -fEx;9 x@  xn#3

    8ractical 8roblem8ractical 8roblem8ractical 8roblem

     y f x x xn= ( , ,..., )1 2

    ;tatistical 8roblem;tatistical 8roblem;tatistical 8roblem

    "hat are the JsK

    "hat is the relationship of the &sK

    8ractical ;olution8ractical ;olution8ractical ;olution ;tatistical ;olution;tatistical ;olution;tatistical ;olution

    "hat are the main inputs? their effectsand optimum values

    D)FI) M)/S5)

    IM$4V)C4&4L

    //L-S)

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    1B1B

    Six Sigma oadmap $hases ' &ools

    Control Plans

    Capability Study

    Design of ExperimentsComponents of Variation Study

    Statistical Process Control

    Measurement Systems Analysis

    Potential Failure Mode Effects Analysis

    Cause & Effect Matrix

    Tougt & Process Map

    VSM

    Define Measure Analy!e "mpro#e Control

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    1-1-

    Logic %ehind a Six Sigma $roHect

    MM   AA   II   CCDEFINEDEFINE

    Clarify business

    strategy andcustomer input

    Assign resources:

    Champion, BB, GB,other

    Select projects:

    VSM, strategy,customers, etc.

    Define project teamand revie !

    support structure

    Determine majoroutputs: Big "#s$ of

    the project %C&'s(

    Develop initialTougt Map

    Define baseline,and objectives for

    )ey project metrics

    Define Pro$ectCarter and agree

    on savings

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    1,1,

    Logic %ehind a Six Sigma $roHect

    AA   II   CCMEASUREMEASURE

    Develop ProcessMap ith inputs %*s(

    and outputs %ys(

    +pdate TougtMap and revise

    Pro$ect Carter

    Classify inputs %*s(in rocess -ap

    %C ! C(

    Define actions forinputs %*s( ith high/ 0 Control Plan

    Complete MSA forinputs %*s( ! outputs

    of interest

    Develop Causeand Effect Matrix

    1dentify )ey inputs%top *s( from C23

    -atri* *

    Define baseline for)ey outputs %ys(

    SPC ! Capability

    Complete FMEA for)ey inputs %top *s(

    DD

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    Logic %ehind a Six Sigma $roHect

    II   CCANALYZEANALYZE

    Define majoreffects: )ey inputs 0

    outputsMulti%Vari C'V

    Develop Design of3*periments plan

    +nderstand effects:Ci%S(uare,A)'VA and*egression

    Define improvementopportunities and

    update TougtMap

    Define relationshipsbeteen inputs and

    outputs 0 y+f,x-

    Conduct Design ofExperiments 0

    D43

    Define ho toeliminate ! reduce

    output variation %ys(

    -onitor process forcritical *s and ys

    SPC ! Capability 

    Conductconfirmation studies

    and D43s

    DD   MM

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    2121

    Logic %ehind a Six Sigma $roHect

    CCIMPROVEIMPROVE

    1mplement processimprovements forcritical *s and ys

    Conduct D'E optimi5ation studies

    %/esponse

    Surface(

    Continue to learnabout y+f,x- andupdate Tougt

    Map

    +pdate Pro$ectCarter

    Document ! monitorimprovements

    SPC ! Capability

    +pdate Process Map, MSA, FMEA and Control Plan 

    Define follo6upactions and

    responsibilities

    Define financialimpact of

    improvements

    DD   MM   AA

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    2222

    Logic %ehind a Six Sigma $roHect

    CONTROLCONTROL

    Define controlmethods for critical

    *s ! ys: Control

    Plan

    3stablish ! revie'uality System

    procedures

    7inali5e ProcessMap and FMEA

    +pdate Pro$ectTrac.ing and Cost

    'ut

    3nsure capablemeasurementsystems: MSA

    3stablish processcontrol for critical

     *s ! ys: SPC

    Document product !process changes

    Assure that gainsare sustained

    7inali5e financialbenefits ith

    Controller

    DD   MM   AA   II

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    2

    Lean ' Six Sigma

    LEA5 +A5UAC=UI5 =AI5I5 @ =FFL;

    LEA5 ;I ;I+A  MELLF" NEL= =AI5I5 @ =FFL;

    =EFM F CF5;=AI5=; /=FC0

    Chec# out my other itemsGClic+ Lin+