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“ No quality assurance program, whether it be voluntary or imposed can correct frequent mistakes and unreliable performance introduced by insufficient training, inadequate laboratory environment, and poor administrative practices.”
Six Sigma – Improvement Focus Define Focus What is the problem? Measure Focus What are we doing, and how well are we doing it? Analyse Focus What is the root cause? Improve Focus Get from the problem statement to the goal statement Control Focus Sustain the gain
Define Opportunities Measure Performance Define Opportunities Analyse Opportunity Improve Performance Control Performance Objective Main Activities Potential Tools and Techniques
To identify and/ or validate the improvement opportunity,
Improve Performance Objective Main Activities Potential Tools and Techniques
To identify, evaluate, and select the right improvement solutions.
To develop a change management approach to assist the organisation in adapting to the changes introduced through solution implementation.
Generate Solution Ideas
Determine Solution Impacts: Benefits
Evaluate and Select Solutions
Develop Process Maps & High Level Plan
Develop and Present Storyboard
Communicate Solutions to all Stakeholders
Output Design of Experiment Analysis / Screening Response Surface Define Opportunities Improve Performance Measure Performance Analyse Opportunity Control Performance
Control Performance Objective Main Activities Potential Tools and Techniques To understand the importance of planning and executing against the plan and determine the approach to be taken to assure achievement of the targeted results. To understand how to disseminate lessons learned, identify replication and standardisation opportunities/ processes, and develop related plans.
Process Owner takes responsibility
Everyone wants to move on
Most challenging phase
Develop Pilot Plan & Pilot Solution
Verify Reduction in Root Cause Sigma Improvement Resulted from Solution
Identify if Additional Solutions are Necessary to Achieve Goal
Identify and Develop Replication & Standardisation Opportunities
Integrate and Manage Solutions in Daily Work Processes
Integrate Lessons Learned
Identify Teams Next Steps & Plans for Remaining Opportunities
Define Project Charter Problem Statement: Goal: Business Case: Scope: Cost Benefit Projection: Milestones: VOC Key Issue CTQ Delighters More Is Better Must Be Voice of the Customer Business Case Initial Process Mapping Outputs Process Inputs Yield: 60% Yield: 90% Yield: 45% Yield: 98% CUSTOMERS SUPPLIERS
Measure Col # 1 2 3 4 5 6 Inspector A B Sample # 1st Trial 2nd Trial Diff 1st Trial 2nd Trial Diff 1 2.0 1.0 1.0 1.5 1.5 0.0 2 2.0 3.0 1.0 2.5 2.5 0.0 3 1.5 1.0 0.5 2.0 1.5 0.5 4 3.0 3.0 0.0 2.0 2.5 0.5 5 2.0 1.5 0.5 1.5 0.5 1.0 Totals 10.5 9.5 3.0 9.5 8.5 2.0 Averages 2.1 1.9 0.6 1.9 1.7 0.4 Sum 4.0 Sum 3.6 X A 2.0 X B 1.8 R A R B Validate Measurement Systems Display Data 0 1000 -1000 10 20 30 UCL X LCL D B F A C E Other Identify the Metrics Data Collection Plan Operational Definition and Procedures Data Collection Plan What questions do you want to answer? Data What Measure type/ Data type How measured Related conditions Sampling notes How/ where How will you ensure consistency and stability? What is your plan for starting data collection? How will the data be displayed? Prioritise the Metrics I1 I2 I3 I4 O1 O2 O3 O4 FMEA Identify Process Capability LSL USL Cp = 0.4 s = 2.7 Measure the process I P O Input Measures Process Measures Output Measures
Analyse VA NVA Process Door Regression Analysis Chi-Square c ² Regression t-test ANOVA X 1 Y Hypothesis-Testing Design of Experiments Cause & Effect Data Door 22 21 20 19 18 17 16 15 14 13 12 1 2 3 4 5 6 7 8 9 10 X O n X O n X O n X O n X O n X O n X O n X O n O n X O n .
Improve Perform Cost-Benefit Analysis Generate Solutions A B C D 4 1 3 2 Assess Risks Run Pilot Test Full scale Original 2 4 8 6 10 G 1 3 5 7 9 A B C D F E J I H G Plan Implementation Select the Solution FMEA
Control Evaluate Project Results . Ownership & Monitoring Process Change Management Key Learnings QC Process Chart Document & Standardise . Closure Process Owner UCL LCL Before After Step 4 changes implemented } Improvement Target } Remaining Gap Good } Improvement Before After A1 A2 A3 A4 A2 A1 A3 A4 Learnings Recommendations Results • • • next Work Instructions Control/Check Points Response to Abnormality Notes Code # Charac- teristics Control Limits Method Who Immediate Fix Permanent Fix Who Flowchart 2 12 Product Name Process Name Process Code # Date of Issue: Issued by: Approved by: Revision Date Reason Signature 1 Operating Procedures Training Curriculum Training Manual Manual Fill to here LSL USL s = 3.7 Cp = 1.4 s = 2.7 Cp = 0.4