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Contents
Six Sigma History & Introduction
Overview of DMAIC Methodology
Define Phase
Measure Phase
Analyze Phase
Improve Phase
Control Phase
Defect Reduction,
Yield Improvement,
Improved Customer Satisfaction,
Higher Net Income &
Continual Improvement and Business Excellence
4
`
5
Mean =
+1
Upper
Spec
? Times
+1 +2 +3 +4 +5 +6
Z = (USL - x) / S
or
Z = (x - LSL) / S
Mean / Target
Upper
Specification Limit
Higher
Probability
of Failure
66807 Defects
Per Million
Opportunities
3 1s
Higher this
these
numbers,
number,
Lower the
chance of
producing a
defect
3 1s
6 2s
Much Lower
Probability
of Failure
3.4 Defects
Per Million
Opportunities
6 2s
7
Cost of Quality
Not Applicable
66,807
25-40% of Sales
15-25% of Sales
233
5-15% of Sales
< 1% of Sales
Source: Six Sigma by Mikel Harry
Unknown
Brainstorming
DMAIC
Task force
Solution
Known
Known
Root Cause
Unknown
11
Cause
Cause
Cause
Cause
Cause
Cause
Single cause
Why Why Analysis
Multiple causes
Fish Bone Analysis
12
13
14
15
16
1.
Deployment Champion :
Responsible for the overall Six Sigma program within the
company
Reviews projects periodically
Adds value in project reviews since he is hands-on in the
business
Clears road blocks for the team
Has the overall responsibility for the project closure
17
2.
Process Owner :
Takes over the project after completion
Manages the control system after turnover
3.
Project Sponsor :
Head of Deptt. Where the project is being run
Acts as a surrogate process owner until an owner is
named
Updates tracker with relevant documents & project data
Part of Senior Mgmt. responsible for selection / approval
of projects
18
Project Leader
4.
5.
6.
Team Members :
Chosen for specific skill or competency
Helps in designing the new process
Drive the project to completion
19
Define Phase
20
Define Phase
21
Step 1
Step 2
Select Project
Step 3
22
COPQ
Identification of
CTQs
23
24
Output Measures
Y= f (X)
To get results, should we focus our behavior on the Y or X ?
Y
Dependent
Output
Effect
Symptom
Monitor
Response
X1 . . . XN
Independent
Input-Process
Cause
Problem
Control
Factor
25
Primary Metric :
Secondary Metric :
27
4.
5.
6.
Business Case
Project Scope
Opportunity or Problem Statement
Goal Statement
Team Selection
Project Plan
28
Project
Scope
Problem
Statement
What are the boundaries of the initiative (Start & End Points of the
process) ?
What is not within the scope ?
Team
Selection
Project
Plan
S
Supplier
I
Input
Measures
Requirements
Process
Output
C
Customer
Measures
Process
Map
Input
Process
Measurable
Requirements
Key Process
Steps
Outputs
Output
Measurable
Requirements
Customers
Start
point
1
2
3
4
5
6
7
End Point
33
Project Name:
Project Champion:
Business Case:
Project Details
Problem Statement:
Goal/Objective:
Project Scope/Constraints:
Constraint :
Sr. No.
Name
Scope
Dept.
Signature
1
2
3
4
5
6
Baseline for Project
Project Metric(s)/ KPI name:
Project Metric(s)/ KPI Value at start:
Criteria for selecting Baseline value:
Benefits
Start
Define
Measure
Analyse
Improve
Control
Closure and handover
Other benefits
OE
Champion
Sign
Name:
Sign
Authorisation
Project Champion
Name:
Finance representative
Sign
Name:
Sign
34
35
Measure Phase
36
Step 4
Finalize Project Y
Performance Standards for Y
Step 5
Validate Measurement
System for Y
Step 6
Measure Current
Performance & Gap
37
38
39
Analyze Phase
40
Step 7
Step 8
Identify Critical Xs
Step 9
41
43
Graphical Analysis
Pareto Plots for prioritization
Box Plots, Histogram & Scatter Diagram
44
45
M A
Improve Phase
46
Step 10
Step 11
Step 12
47
M A
48
Brainstorming
M A
49
Control Phase
50
Step 13
Step 14
Step 15
51
Control Plan
Documentation of Project Findings
Training & Communication Plan
Transfer to Process Owner
Validation of Financial Benefits
53
over time
Identifies specific actions & tools required for sustaining process gains
The objective is :
To ensure that our process stays in control after the solution has been
implemented.
To quickly detect the out of control state and determine the associated
special causes so that action can be taken to correct the problem
before non conformances are produced
Elements of Control Plan
Process Documentation
Mistake Proofing Systems
Process Ownership
Audit / Inspection Plans
55
56
57