Hi everybody
We (hsqs.in) are going to provide you Six Sigma knowledge by our ppt presentation.
If you face any problem in understanding of six sigma then please send me your questions on our provided email I.D , we will send you solution of As soon as possible .
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Kumar Kunal
krkunal@rediffmail.com
kumar.kunal@hsqs.in
Hi everybody
We (hsqs.in) are going to provide you Six Sigma knowledge by our ppt presentation.
If you face any problem in understanding of six sigma then please send me your questions on our provided email I.D , we will send you solution of As soon as possible .
Regards
Kumar Kunal
krkunal@rediffmail.com
kumar.kunal@hsqs.in
Hi everybody
We (hsqs.in) are going to provide you Six Sigma knowledge by our ppt presentation.
If you face any problem in understanding of six sigma then please send me your questions on our provided email I.D , we will send you solution of As soon as possible .
Regards
Kumar Kunal
krkunal@rediffmail.com
kumar.kunal@hsqs.in
Hi everybody
We (hsqs.in) are going to provide you Six Sigma knowledge by our ppt presentation.
If you face any problem in understanding of six sigma then please send me your questions on our provided email I.D , we will send you solution of As soon as possible .
Regards
Kumar Kunal
krkunal@rediffmail.com
kumar.kunal@hsqs.in
" To rise to withstand hard core competition one needs to alter policies Six Sigma was my seminar topic in my college It helped me in my academics so standards upgraded that to achievable in any institute any field you are it serves its role.
six sigma is a vibrant topic in quality management
i had made this one in my total quality management subject in mba.
u can take this but leave a comment if u like it
Quality Improvement in Low Pressure Die Casting Of Automobile Cylinder Head U...paperpublications3
Abstract: Six Sigma is one of the best developing methodologies for quality confirmation and administration in Automobile parts manufacturing. In this research, Quality management tools such as Data Analysis, Pareto charts, Cause and Effect diagrams, Process capability study, Failure Mode Effect Analysis(FMEA), Design of Experiments(DOE), Visual and Control charts etc. are used in characterizing the problems to discover the underlying drivers for the problems and doing tests so as to propose improvements, through which the organization could acquire quality and soundness all the while. The project will be focused on the quality improvement of major defect in cylinder head which were produced by low pressure die casting machines in an Auto mobile manufacturing company. In this project the main defect cause this rejection is “Misrun” which is observed in low pressure die casting of cylinder head. Using the Six Sigma method the DPMO reduces from 16400 to 7800. Further improvement in the rejection is expected in the long run after the continous implementation of all the solutions.
Six Sigma is a disciplined, data-driven approach and methodology for eliminating defects (driving toward six standard deviations between the mean and the nearest specification limit) in any process – from manufacturing to transactional and from product to service.
Unit 8 - Information and Communication Technology (Paper I).pdfThiyagu K
This slides describes the basic concepts of ICT, basics of Email, Emerging Technology and Digital Initiatives in Education. This presentations aligns with the UGC Paper I syllabus.
" To rise to withstand hard core competition one needs to alter policies Six Sigma was my seminar topic in my college It helped me in my academics so standards upgraded that to achievable in any institute any field you are it serves its role.
six sigma is a vibrant topic in quality management
i had made this one in my total quality management subject in mba.
u can take this but leave a comment if u like it
Quality Improvement in Low Pressure Die Casting Of Automobile Cylinder Head U...paperpublications3
Abstract: Six Sigma is one of the best developing methodologies for quality confirmation and administration in Automobile parts manufacturing. In this research, Quality management tools such as Data Analysis, Pareto charts, Cause and Effect diagrams, Process capability study, Failure Mode Effect Analysis(FMEA), Design of Experiments(DOE), Visual and Control charts etc. are used in characterizing the problems to discover the underlying drivers for the problems and doing tests so as to propose improvements, through which the organization could acquire quality and soundness all the while. The project will be focused on the quality improvement of major defect in cylinder head which were produced by low pressure die casting machines in an Auto mobile manufacturing company. In this project the main defect cause this rejection is “Misrun” which is observed in low pressure die casting of cylinder head. Using the Six Sigma method the DPMO reduces from 16400 to 7800. Further improvement in the rejection is expected in the long run after the continous implementation of all the solutions.
Six Sigma is a disciplined, data-driven approach and methodology for eliminating defects (driving toward six standard deviations between the mean and the nearest specification limit) in any process – from manufacturing to transactional and from product to service.
Unit 8 - Information and Communication Technology (Paper I).pdfThiyagu K
This slides describes the basic concepts of ICT, basics of Email, Emerging Technology and Digital Initiatives in Education. This presentations aligns with the UGC Paper I syllabus.
Model Attribute Check Company Auto PropertyCeline George
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Instructions for Submissions thorugh G- Classroom.pptxJheel Barad
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The Roman Empire A Historical Colossus.pdfkaushalkr1407
The Roman Empire, a vast and enduring power, stands as one of history's most remarkable civilizations, leaving an indelible imprint on the world. It emerged from the Roman Republic, transitioning into an imperial powerhouse under the leadership of Augustus Caesar in 27 BCE. This transformation marked the beginning of an era defined by unprecedented territorial expansion, architectural marvels, and profound cultural influence.
The empire's roots lie in the city of Rome, founded, according to legend, by Romulus in 753 BCE. Over centuries, Rome evolved from a small settlement to a formidable republic, characterized by a complex political system with elected officials and checks on power. However, internal strife, class conflicts, and military ambitions paved the way for the end of the Republic. Julius Caesar’s dictatorship and subsequent assassination in 44 BCE created a power vacuum, leading to a civil war. Octavian, later Augustus, emerged victorious, heralding the Roman Empire’s birth.
Under Augustus, the empire experienced the Pax Romana, a 200-year period of relative peace and stability. Augustus reformed the military, established efficient administrative systems, and initiated grand construction projects. The empire's borders expanded, encompassing territories from Britain to Egypt and from Spain to the Euphrates. Roman legions, renowned for their discipline and engineering prowess, secured and maintained these vast territories, building roads, fortifications, and cities that facilitated control and integration.
The Roman Empire’s society was hierarchical, with a rigid class system. At the top were the patricians, wealthy elites who held significant political power. Below them were the plebeians, free citizens with limited political influence, and the vast numbers of slaves who formed the backbone of the economy. The family unit was central, governed by the paterfamilias, the male head who held absolute authority.
Culturally, the Romans were eclectic, absorbing and adapting elements from the civilizations they encountered, particularly the Greeks. Roman art, literature, and philosophy reflected this synthesis, creating a rich cultural tapestry. Latin, the Roman language, became the lingua franca of the Western world, influencing numerous modern languages.
Roman architecture and engineering achievements were monumental. They perfected the arch, vault, and dome, constructing enduring structures like the Colosseum, Pantheon, and aqueducts. These engineering marvels not only showcased Roman ingenuity but also served practical purposes, from public entertainment to water supply.
Synthetic Fiber Construction in lab .pptxPavel ( NSTU)
Synthetic fiber production is a fascinating and complex field that blends chemistry, engineering, and environmental science. By understanding these aspects, students can gain a comprehensive view of synthetic fiber production, its impact on society and the environment, and the potential for future innovations. Synthetic fibers play a crucial role in modern society, impacting various aspects of daily life, industry, and the environment. ynthetic fibers are integral to modern life, offering a range of benefits from cost-effectiveness and versatility to innovative applications and performance characteristics. While they pose environmental challenges, ongoing research and development aim to create more sustainable and eco-friendly alternatives. Understanding the importance of synthetic fibers helps in appreciating their role in the economy, industry, and daily life, while also emphasizing the need for sustainable practices and innovation.
Ethnobotany and Ethnopharmacology:
Ethnobotany in herbal drug evaluation,
Impact of Ethnobotany in traditional medicine,
New development in herbals,
Bio-prospecting tools for drug discovery,
Role of Ethnopharmacology in drug evaluation,
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How to Split Bills in the Odoo 17 POS ModuleCeline George
Bills have a main role in point of sale procedure. It will help to track sales, handling payments and giving receipts to customers. Bill splitting also has an important role in POS. For example, If some friends come together for dinner and if they want to divide the bill then it is possible by POS bill splitting. This slide will show how to split bills in odoo 17 POS.
2. Topics (Session 1)
♦ Understanding Six Sigma
♦ History of Six Sigma
♦ Six Sigma Methodologies & Tools
♦ Roles & Responsibilities
♦ How YOU can use Six Sigma
3. Six Sigma is. . .
♦ A performance goal, representing 3.4 defects for
every million opportunities to make one.
♦ A series of tools and methods used to improve or
design products, processes, and/or services.
♦ A statistical measure indicating the number of
standard deviations within customer expectations.
♦ A disciplined, fact-based approach to managing a
business and its processes.
♦ A means to promote greater awareness of
customer needs, performance measurement, and
business improvement.
4. What’s in a name?
♦ Sigma is the Greek letter representing the standard
deviation of a population of data.
♦ Sigma is a measure
of variation
(the data spread)
σ
μ
5. What does variation mean?
20
♦ Variation means that a 15
process does not produce 10
the same result (the “Y”) 5
every time. 0
-5
♦ Some variation will exist in
-10
all processes.
♦ Variation directly affects customer experiences.
Customers do not feel averages!
6. Measuring Process Performance
The pizza delivery example. . .
♦ Customers want their pizza
delivered fast!
♦ Guarantee = “30 minutes or less”
♦ What if we measured performance and found an
average delivery time of 23.5 minutes?
– On-time performance is great, right?
– Our customers must be happy with us, right?
7. How often are we delivering on
time?
Answer: Look at 30 min. or less
the variation!
s
0 10 20 x 30 40 50
♦ Managing by the average doesn’t tell the whole story. The
average and the variation together show what’s happening.
8. Reduce Variation to Improve
Performance
How many standard 30 min. or less
deviations can you
“fit” within
s
customer
expectations?
0 10 20 x 30 40 50
♦ Sigma level measures how often we meet (or fail to meet)
the requirement(s) of our customer(s).
9. Managing Up the Sigma Scale
Sigma % Good % Bad DPMO
1 30.9% 69.1% 691,462
2 69.1% 30.9% 308,538
3 93.3% 6.7% 66,807
4 99.38% 0.62% 6,210
5 99.977% 0.023% 233
6 99.9997% 0.00034% 3.4
10. Examples of the Sigma Scale
In a world at 3 sigma. . . In a world at 6 sigma. . .
♦ There are 964 U.S. flight ♦ 1 U.S. flight is cancelled every
cancellations per day. 3 weeks.
♦ The police make 7 false arrests ♦ There are fewer than 4 false
every 4 minutes. arrests per month.
♦ In MA, 5,390 newborns are ♦ 1 newborn is dropped every 4
dropped each year. years in MA.
♦ In one hour, 47,283 ♦ It would take more than
international long distance calls 2 years to see the same number
are accidentally disconnected. of dropped international calls.
11. Topics
♦ Understanding Six Sigma
♦ History of Six Sigma
♦ Six Sigma Methodologies & Tools
♦ Roles & Responsibilities
♦ How YOU can use Six Sigma
12. The Six Sigma Evolutionary Timeline
1818: Gauss uses the normal curve 1924: Walter A. Shewhart introduces
to explore the mathematics of error the control chart and the distinction of
analysis for measurement, probability special vs. common cause variation as
analysis, and hypothesis testing. contributors to process problems.
1736: French 1896: Italian sociologist Vilfredo
mathematician Alfredo Pareto introduces the 80/20
Abraham de rule and the Pareto distribution in
Moivre publishes Cours d’Economie Politique.
an article
introducing the
normal curve.
1949: U. S. DOD issues Military
Procedure MIL-P-1629, Procedures
1960: Kaoru Ishikawa
for Performing a Failure Mode Effects
introduces his now famous
and Criticality Analysis.
cause-and-effect diagram.
1941: Alex Osborn, head of 1970s: Dr. Noriaki Kano
BBDO Advertising, fathers a introduces his two-dimensional
widely-adopted set of rules for quality model and the three
“brainstorming”. types of quality.
1986: Bill Smith, a senior engineer
and scientist introduces the 1995: Jack Welch
concept of Six Sigma at Motorola launches Six Sigma at
GE.
1994: Larry Bossidy launches
Six Sigma at Allied Signal.
15. Topics
♦ Understanding Six Sigma
♦ History of Six Sigma
♦ Six Sigma Methodologies & Tools
♦ Roles & Responsibilities
♦ How YOU can use Six Sigma
16. DMAIC – The Improvement
Methodology
Define Measure Analyze Improve Control
Objective: Objective: Objective: Objective: Objective:
DEFINE the MEASURE current ANALYZE the IMPROVE the CONTROL the
opportunity performance root causes of process to process
problems eliminate root to sustain the gains.
causes
Key Define Tools: Key Measure Key Analyze Key Improve Key Control
• Cost of Poor Tools: Tools: Tools: Tools:
Quality (COPQ) • Critical to Quality • Histograms, • Solution • Control Charts
• Voice of the Requirements Boxplots, Multi- Selection Matrix • Contingency
Stakeholder (CTQs) Vari Charts, etc. • To-Be Process and/or Action
(VOS) • Sample Plan • Hypothesis Tests Map(s) Plan(s)
• Project Charter • Capability • Regression
• As-Is Process Analysis Analysis
Map(s) • Failure Modes
• Primary Metric and Effect
(Y) Analysis (FMEA)
17. Define – DMAIC Project
What is the project?
$
Project Cost of
Charter Poor Voice of
Quality S ta k e h o ld e r s the
Stakeholde
r
Six Sigma
♦ What is the problem? The “problem” is the Output (a “Y”
in a math equation Y=f(x1,x2,x3) etc).
♦ What is the cost of this problem
♦ Who are the stake holders / decision makers
♦ Align resources and expectations
18. Define – As-Is Process
How does our existing process work?
Move-It! Courier Package Handling
Process
Accounts Accounts
Courier Mail Clerk In-SortClerk In-SortSupervisor DistanceFeeClerk WeightFeeClerk Out-SortClerk Out-SortSupervisor
ReceivableClerk Supervisor
Observ e package
weight (1 or 2) on
back of package
Look up
appropriate
Weight Fee and
write in top middle
box on package
back
Add Distance &
Take packages
Weight Fees
f rom Weight Fee
together and write
Clerk Outbox to
in top right box on
A/R Clerk Inbox.
package back
Circle Total Fee
Does EVERYONE and Draw Arrow
f rom total to
sender code
agree how the current
Accounting
Take packages Write Total Fee
f rom A/R Clerk f rom package in
process works?
Outbox to appropriate
Accounts Sender column on
Superv isorInbox. Accts. Supv .’s log
Take packages
Draw 5-point Star
f rom Accounts
in upper right
Superv isor
corner of package
Outbox to Out-
f ront
Sort Clerk Inbox.
Define the Non Value
Sort packages in
order of Sender
Code bef ore
placing in outbox
Take packages
Add steps Add up Total # of Observ e sender
Finalizing
f rom Out-Sort Packages and and receiv er
Clerk Outbox to Total Fees f rom codes and make
Out-Sort log and create entry in Out-Sort
Superv isorInbox. client inv oice Superv isor’s log
Deliv erPackages
Delivery
to customers
according to N, S,
E, W route
Deliv er inv oiceto
client
Submit log to
Submit log to Submit log to
General Manager
General Manager General Manager
at conclusion of
at end of round at end of round
round.
19. Define – Customer Requirements
What are the CTQs? What motivates the customer?
Voice of the Customer Key Customer Issue Critical to Quality
SECONDARY RESEARCH
Market
Data Industry
l e n yrt s udn
I
Benchmarking
Customer
t I
Correspondence
Customer
Service
s s o P gn ne s L
i t i
PRIMARY RESEARCH
t
Surve
Surve
ys
ys
OTM
Obser-
Focus Groups vations
20. Measure – Baselines and
Capability
What is our current level of performance?
Descriptive Statistics
♦ Sample some data / not all data Variable: 2003 Output
♦ Current Process actuals measured against Anderson-Darling Normality Test
A-Squared: 0.211
P-Value: 0.854
the Customer expectation Mean
StDev
23.1692
10.2152
♦
Variance 104.349
What is the chance that we will succeed Skewness
Kurtosis
N
0.238483
0.240771
100
0 10 20 30 40 50
at this level every time? Minimum
1st Quartile
0.2156
16.4134
Median 23.1475
3rd Quartile 29.6100
Maximum 55.2907
Pareto Chart for Txfr Defects 95% Confidence Interval for Mu
95% Confidence Interval for Mu
21.1423 25.1961
19.5 20.5 21.5 22.5 23.5 24.5 25.5 26.5 95% Confidence Interval for Sigma
100 100 8.9690 11.8667
95% Confidence Interval for Median
95% Confidence Interval for Median
80 19.7313 26.0572
60
Percent
Count
50
40
20
0 0
t
un er s
Defect La
te
A mo Oth
Count 79 17 4
Percent 79.0 17.0 4.0
Cum % 79.0 96.0 100.0
21. Measure – Failures and Risks
Where does our process fail and why?
Subjective opinion mapped into an “objective” risk profile number
Failure Modes and Effects Analysis (FMEA)
Process/Product
Process or
Prepared by: Page ____ of ____
Product Name:
Responsible: FMEA Date (Orig) ______________ (Rev) _____________
Process S O D R S O D R
Step/Part E C E P Actions E C E P
Number Potential Failure Mode Potential Failure Effects V Potential Causes C Current Controls T N Recommended Resp. Actions Taken V C T N
X1 0
0
0
0
X2
0 0
0 0
X3
0 0
0 0
X4
0 0
0 0
0 0
etc 0
0
0
0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
22. Analyze – Potential Root Causes
What affects our process?
Ishikawa Diagram
(Fishbone)
Six Sigma
y = f (x1, x2, x3 . . . xn)
23. Analyze – Validated Root Causes
What are the key root causes?
Pareto Chart for Txfr Defects
100 100
80
Percent
60
Count
50
40
20
0 0
nt er s
E x p e r im e n t a l D e s ig n
Defect La
te
Am
ou
Oth
Count 79 17 4
Percent 79.0 17.0 4.0
Cum % 79.0 96.0 100.0
Data Regression
Stratification Analysis
Pareto Chart for Amt Defects
15
100
80
Process
Simulatio
Percent
60
Count
10
40
5
20
n
0 0
cy al er
Defect Cu
rren Cle
ric
Oth
Count 12 3 2
Percent 70.6 17.6 11.8
Cum % 70.6 88.2 100.0
Six Sigma
y = f (x1, x2, x3 . . . xn)
Critical Xs
24. Improve – Potential Solutions
How can we address the root causes we identified?
♦ Address the causes, not the symptoms.
Generate
Evaluate
Clarify
Decision
y = f (x1, x2, x3 . . . xn)
Critical Xs
Divergent | Convergent
25. Improve – Solution Selection
How do we choose the best solution?
Solution Selection Matrix
Qualit
Solution Sigma Time CBA Other Score
y
Time Cost
Right
Six Sigma
Solution
Wrong
Nice
☺ Try
Solution
Implementatio
Nice n Plan
X
doo G da B
not a ne ml p m
e I
Idea
i t
26. Control – Sustainable Benefits
How do we ”hold the gains” of our new process?
♦ Some variation is normal and OK
♦ How High and Low can an “X” go yet not materially impact the “Y”
♦ Pre-plan approach for control exceptions
Process Control System (Business Process Framework)
Process Owner: Direct Process Customer: Date:
Process Description: CCR:
Flowchart Measuring and Monitoring
Measures
Key Specs
(Tools) Responsibility Contingency
Measure &/or Remarks
Where & (Who) (Quick Fix)
ments Targets
Frequency
P1 - activity 35
duration,
min. UCL=33.48
P2 - # of
incomplete
Individual Value
loan
applications
25
Mean=24.35
15 LCL=15.21
0 10 20 30
Observation Number
27. DFSS – The Design Methodology
Design for Six Sigma
Define Measure Analyze Develop Verify
♦ Uses
– Design new processes, products, and/or services from scratch
– Replace old processes where improvement will not suffice
♦ Differences between DFSS and DMAIC
– Projects typically longer than 4-6 months
– Extensive definition of Customer Requirements (CTQs)
– Heavy emphasis on benchmarking and simulation; less emphasis
on baselining
♦ Key Tools
– Multi-Generational Planning (MGP)
– Quality Function Deployment (QFD)
28. Topics
♦ Understanding Six Sigma
♦ History of Six Sigma
♦ Six Sigma Methodologies & Tools
♦ Roles & Responsibilities
♦ How YOU can use Six Sigma
29. Champions
♦ Promote awareness and execution of Six Sigma
within lines of business and/or functions
♦ Identify potential Six Sigma projects to be
executed by Black Belts and Green Belts
♦ Identify, select, and support Black Belt and
Green Belt candidates
♦ Participate in 2-3 days of workshop training
30. Black Belts
♦ Use Six Sigma methodologies and advanced tools
(to execute business improvement projects
♦ Are dedicated full-time (100%) to Six Sigma
♦ Serve as Six Sigma knowledge leaders within
Business Unit(s)
♦ Undergo 5 weeks of training over 5-10 months
31. Green Belts
♦ Use Six Sigma DMAIC methodology and basic
tools to execute improvements within their
existing job function(s)
♦ May lead smaller improvement projects within
Business Unit(s)
♦ Bring knowledge of Six Sigma concepts & tools to
their respective job function(s)
♦ Undergo 8-11 days of training over 3-6 months
32. Other Roles
♦ Subject Matter Experts
– Provide specific process knowledge to Six Sigma teams
– Ad hoc members of Six Sigma project teams
♦ Financial Controllers
– Ensure validity and reliability of financial figures used
by Six Sigma project teams
– Assist in development of financial components of
initial business case and final cost-benefit analysis
33. Topics
♦ Understanding Six Sigma
♦ History of Six Sigma
♦ Six Sigma Methodologies & Tools
♦ Roles & Responsibilities
♦ How YOU can use Six Sigma
35. Topics for Detailed Discussion
♦ Problem Identification
♦ Cost of Poor Quality
♦ Problem Refinement
♦ Process Understanding
♦ Potential X to Critical X
♦ Improvement
38. Problem Identification
First Pass Yield (FPY):
The probability that 100 Units
any given unit can go
Step 1 Outputs / Inputs
through a system
defect-free without 100 / 100 = 1
rework. 100
Scrap 10 Units Step 2
90 / 100 = .90
90
Scrap 3 Units Step 3
87 / 90 = .96
87
Scrap 2 Units Step 4 85 / 87 = .97
At first glance, the yield would seem to be When in fact the FPY is (1 x .90 x .96 x .97 = .
85% (85/100 but….) 838)
85
39. Problem Identification
Rolled
100 Units Outputs / Inputs
Throughput
Yield (RTY): Step 1 90 / 100 = .90
The yield of
individual Re-Work
process steps 10 Units 100 Units
multiplied Step 2 97 / 100 = .97
together.
Reflects the
Re-Work
hidden factory 3 Units 100 Units
rework issues
associated with Step 3 98 / 100 = .98
a process.
Re-Work
2 Units 100 Units
Step 4 .90 x .97 x .98 = .855
100 Units
40. Problem Identification
RTY Examples - Widgets
50
Roll Throughput Yield
Function 1 50/50 = 1
(50-5)/50 = .90
50
(50-10)/50 = .80
Function 2
5
(50-5)/50 = .90
50
Function 3
10
1 x .90 x .80 x .90 = .65
50
Function 4
5
Put another way, this process is operating
50 a 65% efficiency
41. Problem Identification
RTY Example - Loan Underwriting
50
Roll Throughput Yield
Application 50/50 = 1
(50-7-2)/50 = .82
2 50 7
Fails (43-6)/43 = .86
Underwrite
Underwriting
(43-1-2)/43 = .93
6 43
Complete Full
Paperwork
1 x .82 x .86 x .93 = .66
2 1
43
Decide not to
Close
borrow
42 Put another way, this process is operating
a 66% efficiency
42. Problem Identification
Histogram – A histogram is a basic graphing tool that displays the
relative frequency or occurrence of continuous data values showing
which values occur most and least frequently. A histogram illustrates the
shape, centering, and spread of data distribution and indicates whether
there are any outliers.
Histogram of Cycle Time
40
30
Frequency
20
10
0
0 100 200 300 400 500
C8
43. Problem Identification
Histogram – Can also help us graphically understand the data
Descriptive Statistics
Variable: CT
Anderson-Darling Normality Test
A-Squared: 6.261
P-Value: 0.000
Mean 80.1824
StDev 67.6003
Variance 4569.81
Skewness 2.31712
Kurtosis 8.26356
N 170
25 100 175 250 325 400
Minimum 1.000
1st Quartile 31.000
Median 66.000
3rd Quartile 105.000
95% Confidence Interval for Mu Maximum 444.000
95% Confidence Interval for Mu
69.947 90.417
54 64 74 84 94 95% Confidence Interval for Sigma
61.098 75.664
95% Confidence Interval for Median
95% Confidence Interval for Median
55.753 84.494
44. Problem Identification
Pareto – The Pareto principle states that 80% of the impact of the
problem will show up in 20% of the causes. A bar chart that displays by
frequency, in descending order, the most important defects.
Pareto Chart for WEB
100
100
80
Percent
60
Count
50
40
20
0 0
EB ers
Defect No
n-W Oth eb)
(W
Count 96 15
Percent 86.5 13.5
Cum % 86.5 100.0
45. Topics (Session 2)
♦ Problem Identification
♦ Cost of Poor Quality
♦ Problem Refinement
♦ Process Understanding
♦ Potential X to Critical X
♦ Improvement
46. Cost of Poor Quality
COPQ - The cost involved in fulfilling the gap between the desired and
actual product/service quality. It also includes the cost of lost opportunity
due to the loss of resources used in rectifying the defect.
Hard Savings - Six Sigma project benefits that allow you to do the same
amount of business with less employees (cost savings) or handle more
business without adding people (cost avoidance).
Soft Savings - Six Sigma project benefits such as reduced time to market,
cost avoidance, lost profit avoidance, improved employee morale,
enhanced image for the organization and other intangibles may result in
additional savings to your organization, but are harder to quantify.
Examples / Buckets–
Roll Throughput Yield Inefficiencies (GAP between desired result and
current result multiplied by direct costs AND indirect costs in the process).
Cycle Time GAP (stated as a percentage between current results and
desired results) multiplied by direct and indirect costs in the process.
Square Footage opportunity cost, advertising costs, overhead costs, etc…
47. Topics (Session 2)
♦ Problem Identification
♦ Cost of Poor Quality
♦ Problem Refinement
♦ Process Understanding
♦ Potential X to Critical X
♦ Improvement
48. Problem Refinement
Multi Level Pareto – Logically Break down initial Pareto data into sub-
sets (to help refine area of focus)
Pareto Chart for WEB
100
100
80
Percent
60
Count
50
40
20
0 0 Pareto Chart for Type
B
WE ers
Defect No
n- Oth eb)
(W 100
Count 96 15 100
Percent 86.5 13.5
80
Cum % 86.5 100.0
Percent
60
Count
50
40
20
0 0
g
oi n
nG
al ime dO ers
Defect An
nu
On
eT
im
e an Oth
eT
On
Count 45 35 13 16
Percent 41.3 32.1 11.9 14.7
Cum % 41.3 73.4 85.3 100.0
49. Problem Refinement
Problem Statement – A crisp description of what we are trying to solve.
Primary Metric – An objective measurement of what we are attempting
to solve (the “y” in the y = f(x1, x2, x3….) calculation).
Secondary Metric – An objective measurement that ensures that a Six
Sigma Project does not create a new problem as it fixes the primary
problem. For example, a quality metric would be a good secondary
metric for an improve cycle time primary metric.
50. Problem Refinement
Fish Bone Diagram - A tool used to solve quality problems by
brainstorming causes and logically organizing them by branches. Also
called the Cause & Effect diagram and Ishikawa diagram
Provides tool for exploring cause / effect and 5 whys
51. Topics (Session 2)
♦ Problem Identification
♦ Cost of Poor Quality
♦ Problem Refinement
♦ Process Understanding
♦ Potential X to Critical X
♦ Improvement
52. Process Understanding
SIPOC – Suppliers, Inputs, Process, Outputs, Customers
You obtain inputs from suppliers, add value through your process, and
provide an output that meets or exceeds your customer's requirements.
53. Process Understanding
Process Map – should allow people unfamiliar with the process to understand
the interaction of causes during the work-flow. Should outline Value Added
(VA) steps and non-value add (NVA) steps.
Full Form
Control Open
Start Size Sorts Pull & Sort
Receipt / Docs
Extract
Ck / Vouch
Verify
Perfection
Requal Group
No
Yes Prep cks,
Remit
Rulrs route Prep cks Ship to IP
Pass 1 Pass 2
vouch
Vouchers
Key from
Balance
Data Cap image
No
Vouch
OK
Inventory Yes
Prep
Folders / Full Form Ship to
Box QCReview Cust
54. Process Understanding
Create daily peak Action
staff need plan Plan
No
Yes Can they Call employee
Add 30% to To Floor
the required make it? (3x)
no.
Operations No Need OJT Yes Make No
Compare to OJT
Re-Tng it?
Check off original Billet rpt
desired
Manually Review
returnee Yes
Update HR Staff
staff & "need No Yes
Billet Request Billet Need re
to retrain" To Floor
-train
list
Add 40% to Call (3x)
Stop!
staff needed
Create Update
Staff No IPS
No
Billet Rev
Do they original Do they No
Send Letters Yes Yes Have we No Yes Have we No Yes Interview / Meet Fleet
Do they want to billet & want to Call Wait Rank as
to desired hired hired New hiring
respond? work this call work this List pre-hire "1 2 3"
staff enough? enough? criteria
peak? uncheck peak?
ed
What if the
HR sends Hire in 1- Yes
returnee is Yes Yes
req for No No 2 order
Start already
staffing (3's are
HR / working here show up No
nos. not Place into Call
Recruit on another Do they Do they orienta
No No placed) dept 3X
program? want to want to tion
Stop! Stop!
Currently stay on the stay on the
send the ltr list list
anyways Wait List Yes
Yes Yes
New &
Other Take off Set 14
Take off Set 14
People IPS month
IPS month
call in system flag (on
system flag (on
IPS?)
IPS?)
schedule Yes No Gen Event Roster
for Reach
rpt in IPS
training
Show No Call Notify
up? 1X HR
Yes
Training Gen rpt for
Ops Kronos
Recruit
Train
No Yes Update
Pass?
IPS
55. Topics (Session 2)
♦ Problem Identification
♦ Cost of Poor Quality
♦ Problem Refinement
♦ Process Understanding
♦ Potential X to Critical X
♦ Improvement
56. Potential X to Critical X
“Y” is the dependent output of a variable process. In other
words, output is a function of input variables (Y=f(x1, x2,
x3…).
Through hypothesis testing, Six Sigma allows one to
determine which attributes (basic descriptor (generally
limited or binary in nature) for data we gather – ie. day of
the week, shift, supervisor, site location, machine type,
work type, affect the output. For example, statistically,
does one shift make more errors or have a longer cycle
time than another? Do we make more errors on Fridays
than on Mondays? Is one site faster than another? Once we
determine which attributes affect our output, we determine
the degree of impact using Design of Experiment (DOE).
57. Potential X to Critical X
A Design of Experiment (DOE) is a structured, organized
method for determining the relationship between factors
(Xs) affecting a process and the output of that process (Y).
Not only is the direct affect of an X1 gauged against Y but
also the affect of X1 on X2 against Y is also gauged. In
other words, DOE allows us to determine - does one input
(x1) affect another input (x2) as well as Output (Y).
58. Potential X to Critical X
DOE Example
Main Effects Plot (data means) for Elapsed
Main Effects Plot –
1.4
Lo
w
Hi g
h
Lo
w
Hig
h
Lo
w
Hig
h
Lo
w
Hig
h
Direct impact to Y
1.3
Elapsed
1.2
1.1
1.0
Jams DCDEL SK P2Jam
Interaction Plot (data means) for Elapsed
1 3 1 3 1 3 1 3
1.50
Jams
1 1.25
3 1.00
1.50
DCDEL
3 1.25
Interaction Plot –
1 1.00
1.50
SK
Impacts of X’s on 3
1
1.25
1.00
each other P2Jam 1.50
3 1.25
1 1.00
59. Potential X to Critical X
DOE Optimizer –
Allows us to
statistically predict the
Output (Y) based on
optimizing the inputs
(X) from the Design of
experiment data.
60. Topics (Session 2)
♦ Problem Identification
♦ Cost of Poor Quality
♦ Problem Refinement
♦ Process Understanding
♦ Potential X to Critical X
♦ Improvement
61. Improvement
Once we know the degree to which inputs (X) affect our
output (Y), we can explore improvement ideas, focusing
on the cost benefit of a given improvement as it relates
to the degree it will affect the output. In other words, we
generally will not attempt to fix every X, only those that
give us the greatest impact and are financially or
customer justified.
62. Control
Once improvements are made, the question becomes, are the
improvement consistent with predicted Design of Experiment
results (ie – are they what we expected) and, are they statistically
different than pre-improvement results.
Process Capability Analysis for Sept
LSL USL
Process Data
USL 0.23000
Within
Target *
LSL -1.00000 Overall
Mean -0.02391
Sample N 23
StDev (Within) 0.166425
StDev (Overall) 0.221880
Potential (Within) Capability
Z.Bench 1.53
Z.USL 1.53
Z.LSL 5.87
Cpk 0.51
-1.0 -0.5 0.0 0.5 1.0
Cpm *
Overall Capability Observed Performance Exp. "Within" Performance Exp. "Overall" Performance
Z.Bench 1.14 % < LSL 0.00 % < LSL 0.00 % < LSL 0.00
Z.USL 1.14 % > USL 13.04 % > USL 6.35 % > USL 12.62
Z.LSL 4.40 % Total 13.04 % Total 6.35 % Total 12.62
Ppk 0.38
63. Control
Control Chart - A graphical tool for monitoring changes that occur
within a process, by distinguishing variation that is inherent in the
process(common cause) from variation that yields a change to the
process(special cause). This change may be a single point or a series
of points in time - each is a signal that something is different from
what was previously observed and measured.
I and MR Chart for Sept
1
Individual Value
0.5 UCL=0.5293
0.0 Mean=0.03
2
-0.5 LCL=-0.4693
Subgroup Sept 13 Sept 20
Date 9/13 9/25
0.7 1
0.6 UCL=0.6134
Moving Range
0.5
0.4
0.3
0.2 R=0.1877
0.1
0.0 LCL=0