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SIX SIGMA
-Quality Improvement Program
PIN CODE:-502313
ABSTRACT: INTRODUCTION:
Six Sigma is a The main objective of any
smarter way to manage business or business is to make profit. For
department. It is a vision of quality that increasing the profit, the selling price
equates with only 3.4 defects for should increase and/or the
million opportunities for each product manufacturing cost should come down.
or service transactions. Strives for Since the price is decided by the
perfection. competition in the market, hence the
We believe that defects only the way to increase the profit is to
free product can be in any organization cut down the manufacturing cost which
implementing six sigma. In this paper, can be achieved only through
we presented an overview of the continuous improvement in the
process which explains how six sigma company’s operation. Six sigma
increase the overall quality quality programs provide an overall
improvement task into a series of framework for continuous
project management stages: Define, improvement in the process of an
Measure, Analyses, Innovation, organization. Six sigma uses facts, data
Improve and Control. We will describe and root cause to solve problems.
dependence of six sigma on Normal EVOLUTION OF SIXSIGMA:
Distribution theory and also process Six sigma background
capability. It gives a small note on the stretches back eighty plus years, from
assumptions made in six sigma management science concepts
methodology of problem solving and developed in the United States to
the key elements involved .A brief Japanese management breakthroughs
view on Defects Per Million to “TOTAL QUALITY “ efforts in
Opportunities (DPMO) Analysis is 1970s and 1980s. But the real impacts
given. can be seen in the waves of change and
Ultimate objectives of the positive results sweeping such
methodology to solve problems, companies as GE, MOTOROLA,
improve the quality, profitability and JOHNSON &JOHNSON and
customers satisfaction. AMERICAN EXPRESS.
CONCEPTS: carried out. This quality equates to
Six sigma is defined a customer 99.99966% defect free products or
oriented, structured, systematic, transactions. High quality
proactive and quantitative company standards do make sense but the
wide approach for continuous cost required to pursue such high
improvement of manufacturing, standards have to be balanced with
services, engineering, suppliers and benefits gained. The six sigma
other business process. It is a statistical processes exposes the root causes
measure of the performance of a and then focuses on the
process or a product. It measures the improvements to achieve the
degree to which the process deviates highest level of quality at
from the goals and then takes efforts to acceptable cost. This is essential to
improve the process to achieve total achieve and maintain a competitive
customer satisfaction. advantage and high levels of
customer satisfaction and loyalty.
Six sigma efforts target three main
areas: When we say that a process
is at six sigma level, such a process
• Improving customer satisfaction.
is normally yield two instances of
• Reducing cycle time.
non-conformances out of every
• Reducing defects. million opportunities for non-
Three key characteristics separates six conformances, provided there is no
sigma from quality programs of the shift in the process average. The
past: same will yield 3.4 instances of
1. Six Sigma is a customer focused. non-conformances out of every
THEORY:
6 SIGMA= 3.4 defects per million
Six Sigma relies on the
Six Sigma equates 3.4
normal distribution theory to
defects for every million parts
predict defect rates. As we all
made or process transactions
know, variation is inevitable in any The upper specification limit (USL)
process. The variation can be due and lower specification limit (LSL) of
to chance causes that are inherent +/- 6σ of the mean with a defect rate
in the process [chance variation] or of 0.002 ppm (refer fig.1).
due to assignable causes that are The process capability index Cp. is
external to the process [Assignable defined as ratio of specification
variation]. If we detect and remove width to PC.
all the assignable causes and bring
Cp= (USL-LSL)/(6σ )
the process under the influence of
Cp. is 2 for a six sigma process,
chance causes, then the process is
which means that the inherent
said to be under statistical control.
process variation is half of the
The process capability (PC) is
specification width.
defined as six times the standard
deviation (σ ). PC represents the
measured inherent reproducibility DEFECTS PER MILLION
process. ANALYSIS:
In practice, most of
the delivered products or services
will have multiple parts and /or
process steps, which represent
opportunities for nonconformities
or defects. For example, which a
watch has numerous parts and
assembly steps. In such cases it is
important to ask questions such as
what is the distribution of defects,
how many units can be expected to
have zero defect, one defect, two
defect, and so on for a given ppm,
what will be the defect rates and
sigma levels for individual parts
and process steps that contributes
to the total unit with a given defect Expected Defects (ppm for each
rate. step) = DPMO x Number of
If the number of observed opportunities (for each step)
nonconformities as “d” out of the Expected defects (ppm for
total number of units produced completed unit) = Sum of expected
“u”. defects of
Defects Per Unit (DPU) = d/u
If each unit manufactured has Individual steps
got “m” number of opportunities
for nonconformance, we can DPMO for completed unit =
compute the Defects Per (Expected defects)/(Total number
Opportunity (DPO) as of
Defect Per Opportunity Opportunities)
(DPO)= DPU/m PROCESS YIELD:
In the calculation of DPO, we are The process yield
taking into consideration only the represents the proportion of defect-
active opportunities (those which free units before testing or repair.
are getting measured) and not the The Poisson Distribution can be
passive opportunities (which are used to calculate the
not getting measured) with in each Yield for a unit if the DPU value is
unit. known.
From this, the DPMO can be YIELD= e^(-DPU)
computed as
If the yield is known for each
Defects Per Million part or process step, the overall
Opportunities (DPMO) = DPO x yield for the process (ROLLED
10^6 THROUGHPUT YIELD [YRT])
The sigma level can be found out from can be computed as the product of
the DPMO value using statistical
yields of individual process steps.
tables. If the DPMO and the number of
defect opportunities are known for This value will be less than
each contributing step, the total DPMO
smallest individual yield since
for the completed unit can be
computed as follows. these are all in fractions. This
clearly shows that for improving
the YRT, the individual yields shall MEASURE and collect
be improved. In other words, for data on the problem and its
minimizing the overall defect rate, potential root causes.
the overall defect rate, the ANALYSE the data
individual defect rates of each part selected determine the real root cause
or process step shall be minimized. (s).
Hence, only with six sigma parts INNOVATE – to identify
and process steps will an the “best” solutions to the problem.
organization experience high YRT
IMPROVE the process,
for complex products with
and then pilot the proposed
numerous parts and process steps.
solution.
CONTROL the new
SIX SIGMA -PROBLEM process to ensure that the
SOLVING PROCESS:
PROCESS improvements are
The sigma of the process, which sustained.
tells us how capable the process is,
can be used to compare similar or
KEY ELEMENTS:
dissimilar process. Such
comparison, known as 1.Management Initiatives