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Introduction To  Six Sigma Asadullah Malik M.Sc. (Computer Eng), P.Eng., MBA, PMP, ASQ-CMQ/OE Director & Chief Trainer, AIMS Inc.  (www.GoToAIMS.com) Prepared By: Asadullah Malik, PMP, P.Eng.
Introduction   ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng.
Why Shall We Apply Six Sigma?  ,[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng.    level  DPMO CP 3  as % of Sales 2 308,537 Not Applicable 3 66,807 25%- 40% 4 6,210 15%- 25% 5 233 5%- 15% 6 3.4 < 1%
Approach & Methodologies ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng.
Design For Six Sigma (DMADOV) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng. Define Design Analyze Measure Verify Optimize
DMAIC Methodology ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],A Prepared By: Asadullah Malik, PMP, P.Eng. Voice of the Customer Measure Improve Analyze Control Define Institutionalize
Define ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng.
Balanced Scorecard ,[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng. ,[object Object],[object Object],[object Object],Y = f(X 1  , X 2 ) i.e. improving customer satisfaction is a function of better quality and lower cost ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],X 1  = f(X 11  , X 12 ) i.e. providing better quality is a function of manufacturing better product and better customer service X 11  = f(X 111  , X 112 ) i.e. manufacturing better product is a function of reducing defects and providing additional features
Kano Model ,[object Object],[object Object],[object Object],[object Object],Attributes Prepared By: Asadullah Malik, PMP, P.Eng.
Quality Function Deployment (QFD) Prepared By: Asadullah Malik, PMP, P.Eng.
Roles and Responsibilities ,[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng. Kick-Off Concept & Eval Design & Plan Dev & Imp Roll Out
Measure ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng.
Data Collection Techniques ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng.
Data Collection Techniques ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng.
Project Planning Tools ,[object Object],For more than one tasks (e.g. for a project where all tasks lie on the critical path) Prepared By: Asadullah Malik, PMP, P.Eng. Term Formula Used For One Task PERT Value  (Expected duration) (Pessimistic+ 4*(Most Likely) + Optimistic) 6 Standard Deviation (Sigma) Pessimistic – Optimistic 6 Variance (Standard Deviation) 2 Term Formula Used PERT Value Sum of PERT Values of individual tasks Standard Deviation Sum of Variances of all the tasks Variance Sum of variances of all the tasks
Project Planning Tools ,[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng. Task Name, Duration (D) Late Finish (LF) Early Finish (EF) Late Start (LS) Early Start (ES) EF = ES + D LS = LF - D
Process Cost Control ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng.
Measurement & Validation Tools ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng. Cp = (USL - LSL)/
Analyze ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng.
Objectives & Tools ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng. Process Map QFD Ishikawa Diagram Sum FMEA
Improve ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng.
Solution Design Matrix (SDM)   ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng.
Some Tools for Improve Phase ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng.
Control ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng.
Some Tools for Control Phase ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng.
CONCLUSION ,[object Object],[object Object],[object Object],Prepared By: Asadullah Malik, PMP, P.Eng.

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Introduction to six sigma (www.gotoaims.com)

  • 1. Introduction To Six Sigma Asadullah Malik M.Sc. (Computer Eng), P.Eng., MBA, PMP, ASQ-CMQ/OE Director & Chief Trainer, AIMS Inc. (www.GoToAIMS.com) Prepared By: Asadullah Malik, PMP, P.Eng.
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  • 10. Quality Function Deployment (QFD) Prepared By: Asadullah Malik, PMP, P.Eng.
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Editor's Notes

  1. 1. Listen to the voice of customer before designing any product or establishing organizational processes to deliver the product or service for meeting customer needs and requirements. 2. Project Based Approach: Unlike traditional quality techniques, six sigma explicitly uses project management concepts, and applies project planning tools e.g. Gantt charts, PERT, planning trees. 3. Process Based Approach: Six sigma project helps to identify problems in organizational processes through detailed process maps identifying relationship and interdependencies between the processes. 4. Quantitative Approach: By using quantitative and statistical analysis, six sigma helps to align project goals with organizational goals by determining that which projects offer maximum benefits at lowest cost. 5. Commitment From All Organizational Levels: To create “Shared Ownership &amp; Responsibility” and to ensure commitment from all levels, six sigma formalizes an organization structure for six sigma projects: Executive Management (also referred to as Deployment Champions) is responsible for sponsorship of six sigma project. Six Sigma Black Belts act as experts for providing guidance and coaching others about the six sigma philosophy. Six Sigma Green Belts serve as a liaison between the Black Belts and the project team. They perform the operations required for the six sigma project and work with the project team to ensure that appropriate deliverables are met. Project team executes the actual project work through guidance provided from six sigma Black belt &amp; Green belt holders. 6. Comprehensiveness: Six Sigma is so comprehensive that it can be applied to companies of all sizes in varying business areas.
  2. If we improve the capability of our processes even by one sigma, then it means at least 10% increase in profits which can translate to millions of dollars.
  3. 1. What customers want: This forms the basis for the QFD and shows what are the requirements of the customer. 2. How to accomplish: This is provided by the organization’s technical team, which highlights how the customer wants can be accomplished. 3. Correlation Matrix: This shows how the customers want correlate with the how to accomplish e.g. if customers want a “small BlackBerry”, how to accomplish shows how to accommodate various PCBs in a smaller dimensions. 4. Relationship: This shows the relationship of how to accomplish with what customers want (i.e. strong relationship, medium relationship, weak relationship or no relationship) 5. Planning (Competitive Evaluation): This shows the company’s products and those of the competitors. By comparing the products, the team would know how the company rates on each of the customer’s wants and helps the company in better understanding competition. 6. Target Values: This refers to the value of the product (or design target) as desired by the company 7. Cost to Accomplish: With the help of finance, the project team determines the cost which will be required to accomplish the target values in “6” above 8. Importance Weighting: This shows the importance of the particular feature (e.g. cost/benefit calculation).