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Six Sigma


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Six Sigma : Concept, Role in Quality, Implementation Techniques and Benefits

Published in: Engineering
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Six Sigma

  3. 3. Current Leadershi p Challenge s Custom er Delight Retainin g People Manufacturin g Cycle Time Keeping up with Technolog y AdvancesReducin g Costs Respondin g More Quickly Structuring for Flexibility Growing Oversea s Markets
  4. 4. SIX SIGMA: INTRODUCTION  Business Improvement Approach  Focus of Six Sigma1  Reducing variability in key product quality characteristics to the level at which failure or defects are extremely unlikely  Tasks through 6σ achieved in corporate business1:  Improving quality critical for customers  Reducing costs Objectives of Six Sigma program: Enhanced product quality, yield and cost – all of which, in turn, improve customer satisfaction2
  5. 5. SIX SIGMA Six Sigma is a set of process improvement techniques and tools in statistical quality control, mainly applied to make customer happier and increase profits
  6. 6. Nσ DPMO* YIELD 1σ 691462 30.8538 2σ 308538 69.1462 3σ 66807 93.3193 4σ 6210 99.3790 5σ 233 99.9767 6σ 3.4 99.9997 * Defects per Million Oppurtunity The term “Sigma (б)” refers to measure of variation.
  7. 7. SIX SIGMA: HISTORY Dr Mikel J Harry wrote a paper relating early failures to Quality in 1986 Bill Smith introduced it at his workplace while working as an engineer at Motorola,USA in 1986 Jack Welch made it central to his business strategy at General Electric,USA in 1995 and made the concept was popularized
  8. 8. Mumbai Dabbawala That's too with limited resources
  9. 9. Criterias for Applying Six Sigma  Project Impact on the bottom line : “$” Profit  Justification to the Quality Gained  Applications – Does it need the SIX SIGMA ?
  10. 10. GE Six Sigma Economics $0 $500 $1,000 $1,500 $2,000 $2,500 1996 1998 2000 2002 6 Sigma Projest Success Cost Benefit
  11. 11. ROLE OF SIX SIGMA  OBJECTIVES OF 6σ :  Improve customer satisfaction  Improve quality of product and service  Reduce process cycle time  Overall cost saving  Development of Staff Skill  Eliminating Waste or Defects  WHERE 6σ IS USED  Manufacturing and service industries  Sales and marketing  Accounting and financing
  12. 12. IMPLEMENTATION OF SIX SIGMA DMAIC DMADV Six Sigma Methodology inspired by Deming's Plan-Do- Check-Act Cycle SIPOC
  13. 13. STEPS DEFINITION TOOLS USED Define Define the problem or project goal that needs to be addressed •FMEA •Process Flow Chart •Value Added Flow Chart Measure Measure the current performance in various aspects. It is a data collection step •MSA •SPC •Histogram and Pareto Chart Analysis Analyse the process to determine root causes of variation, poor performance(defects) • DoE •Why-5 •Cause and Effect Diagram Improve Improve process performance by addressing and eliminating the root causes •5S •TPM •Kaizen Control Control improved process and future process performance •Control Plan •Standardized Work •Check Sheet •SPC DMAIC
  14. 14. STEPS DEFINITION Define Define design goals that are consistent with customer demands and the enterprise strategy Measure Measure and identify CTQs (characteristics that are Critical To Quality), measure product capabilities, production process capability, and measure risks. Analysis Analyze to develop and design alternatives Define Design an improved alternative, best suited per analysis in the previous step Verify Verify the design, set up pilot runs, implement the production process and hand it over to the process owner(s) DMADV  The DMADV methodology, instead of the DMAIC methodology, should be used when:  A product or process is not in existence at your company and one needs to be developed  The existing product or process exists and has been optimized but still
  15. 15. SIPOC  SIPOC is a high-level view of a process  Lean – Six Sigma Approach
  16. 16. SIX SIGMA: BENEFITS  Enhanced ability to provide value to customer  Enhanced understanding of business processes  Reduction of Waste  Improved profit performance  Make customer happier
  17. 17. Summary  Dr. W. Edwards Deming proposed to eliminate slogans and programs to improve quality, rather he advised to work to improve the system and provide information on that.1  Six Sigma is the improvement process in which various techniques and tools are used to decrease variability in production and increase profit with statistical quality control,  DMAIC and DMADV are six sigma implementation methodologies inspired by Sir Deming’s Plan-Do-Check- Act cycle
  18. 18. Questions  Explain Six Sigma and its objectives ?  Enlist Six Sigma methodologies and explain DMAIC ?
  19. 19. References 1. Douglas C. Montgomery, Introduction To Statistical Quality Control, John Wiley & Sons, Fourth Edition, Pg. 23 2. Mikel J. Harry, The Nature of Six Sigma Quality, Motorola Inc., 1986.