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Quality management 2


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Quality management 2

  1. 1. Quality Basic ToolsUnderstanding the SIX SIGMA Aditya
  2. 2. HOW to maintain QPE elements?Define the target (quality planning)Call for QUALITY Inspection (quality control)Redesign (quality improvement)
  3. 3. Quality Control strategyApproaching to SIX SIGMA term strategy
  4. 4. Quality Improvement strategyTake the FMEA (Failures Modes and Effect Analysis)
  5. 5. WHAT is the Purpose?
  6. 6. WHAT is this about?
  7. 7. Introduction to Six SigmaWHAT?A SYMBOL…WHY?To show the industry PERFORMANCEs (quality)
  8. 8. Introduction to Six SigmaHOW?By defining the DPMO (Defects Per Million Opportunity)WHEN?NOW!
  9. 9. Introduction to Six SigmaWHY?TO MAKE BETTER WORLD
  10. 10. Approaching Six Sigma strategyunderstanding
  11. 11. Approaching Six Sigma strategyDefine the CTQ’s (Critical To Quality)How many CTQ will be applied to the products ?
  12. 12. Approaching Six Sigma strategyDefine the total of product (TP) in a periodHow many product has been manufactured?
  13. 13. Approaching Six Sigma strategyDefine the DPMO (defects per million opportunities)On 1000.000 products how many defects?
  14. 14. Approaching Six Sigma strategyConvert it to SIX SIGMA conversion tableYield (success rate) ?Sigma term (long or short)?
  15. 15. Six Sigma conversion table
  16. 16. Approaching Six Sigma strategyLet :Total product manufactured be TpTotal Critical to Quality be nCritical to quality be iDefects total be dDefects per group be di THEN the DPMO is n Σdi i=1DPMO = X 1000.000 Tp x n
  17. 17. Approaching Six Sigma strategy IBM computer manufacturing produces 54.998 IBM 5100 at the beginning of 1975. The CTQ define as 2 groups of requirements which is speed must be more than 975 Mhz, and the CPU unit must not be more than 24 C when operating. Group speed defects 8900, and temperature group defects 8876. define the DPMO. nDPMO = Σdi i=1 X 1000.000 Tp x n
  18. 18. Approaching Six Sigma strategyLet:Total product manufactured be Tp = 54.998Total Critical to Quality be n = 2 groups of requirementsCritical to quality be i = speed and temperatureDefects total be d = d1+d2Defects per group be d1= 8900 , and d2=8876 8900 + 8876DPMO = x 1000.000 54998 x 2
  19. 19. Approaching Six Sigma strategy DPMO = 161.605
  20. 20. Inspect the SIGMA term (long or short)Take the uppersigma term from 161.605 Converting to limitSix Sigma conversion table
  21. 21. Approaching Six Sigma strategyThe six sigma term = 2.40Success rate = 81.6 %
  22. 22. Quality Improvement StrategyFor Production Plan up to 1000.000 products next periodAssumption of defects OP per unit= 1-(success rate/100) = 0.184Assumption of defects OP per period = 0.184 x 1000.000 = 184.000Assumption of success OP per period = 0.816 x 1000.000 = 816.000Success rate = 81.6 %Sigma term = 2.40Next plan : upgrading to sigma 2.50!
  23. 23. Six Sigma conversion table
  24. 24. Approaching Six Sigma strategyThe six sigma term = 2.50Success rate = 84.1 %DPMO = 158.655Gap = DPM(currnt)-DPM(2.50) = 161.605 – 158.655 = 2950 defects
  25. 25. Approaching Six Sigma strategyGap percentage = (2950 / DPMO trget) = (2950 / 158.655) = (1.859%)
  26. 26. Quality Improvements StrategyWe get :Total product manufactured be Tp = 1000.000Total Critical to Quality be n = 2 groups of requirementsCritical to quality be i = speed and temperatureDefects total be d = d1+d2Defects per group be d1= X1 , and d2=X2DPMO = X1 + X2158.655 = x 1000.000 1000.000 x 2
  27. 27. Approaching Six Sigma strategyTotal unit = 1000.000 unitsDefects limit = 317.310 unitsIntensive inspection = 1.859 % x 1000.000 = per 18.590 units
  28. 28. Intensive inspection methodIntroduction to FMEA (Failures Modes and Effect Analysis)Intensive inspection regarding the defects after (n) unitsTo overcome the cases and compare the next inspection for (2n) unitsQuality inspection ROUTINES- Check the list of inspection (based on the CTQ)- Inspect the procedure of most occurs defects product ex: prod line/treatment- Do Research and Development to try other method
  29. 29. Intensive inspection methodThe product is NON conformityWhy? (1)The CPU is hot over the limitWhy? (2)The heat sink is not attached perfectlyWhy? (3)The shock cause it looseWhy? (4)The screw is not tight enoughWhy? (5)NEED loctite for it
  30. 30. Question?Introduction to FMEA (Failures Modes and Effect Analysis)
  31. 31. Quiz?Introduction to FMEA (Failures Modes and Effect Analysis)A SPARK timetravel machine industry produces 263 timetravel (TT)machines. They consider the microsingularities supply must not be higherthan 9 Giga joules and the jump speed must not be less than 10yrs/hr tomake the TT machines effective. After the end of the period, SPARK found34 of their machines are considered as defects. Define what SIX SIGMAterm they are in. and if the SPARK would like to produce 6578 machines inthe next period, what is their defect limit? and per how many machines theymust do the intensive inspection ?