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5s and 6 sigma quality management By

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7/27/12

V.TAMIL SUNDRA ARASU MOORTHI m.Suganya KIRSHAN devi R.YOGESH

SIX SIGMA

Six Sigma is a business management strategy originally developed by Motorola,USA in 1986. developed by Michel J. Harry. it is widely used in many sectors of industry. Six Sigma seeks to improve the quality of process outputs by identifying and removing the causes of defects (errors) and minimizing 7/27/12

Each Six Sigma project carried out within an organization follows a defined sequence of steps and has quantified financial targets (cost reduction and/or profit increase). The term Six Sigma invent from terminology associated with manufacturing, specifically terms associated with statistical modeling of manufacturing processes. The six sigma creates percentage of defect-free products. 7/27/12

SIX SIGMA

A six sigma process is one in which 99.99966% of the products manufactured are statistically expected to be free of defects (3.4 defects per million). Motorola set a goal of "six sigma" for all of its manufacturing operations, and this goal became a byword for the management and engineering practices used to 7/27/12

SIX SIGMA

Six Sigma was heavily inspired by the quality improvement methodologies of the six preceding decades, such as Quality control, Total Quality Management (TQM),

Zero Defects, based on the work of pioneers such as Shewhart, Deming, Juran, Crosby, Ishikawa, Taguchi, and others. 7/27/12

CONCEPT OF SIX SIGMA


Process Variability Cp Total Amount Outside Limits 4.56 % (45,500 ppm) Typical Action to be taken Heavy Process Control, Sorting rework, Etc.

0.67

1.0 3

2700 ppm

Heavy process Control, Inspection

1.33 4

64 ppm

Reduced Inspection, Selected use of Control Charts

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LSL

CONCEPT OF SIX SIGMA


Process Variability Cp Total Amount Typical Action to Outside Limits be taken 1.67 1 ppm Spot Checking, Selected use of Control Charts Reduced for Control, Uniformity in process inputs

2.00

0.01ppm

USL Process 7/27/12

LSL Mean

Cp = Design Width / Process Width Cp = USL LSL / UCL - LCL

SIGMA

SIGMA SCALE OF DEFECTS(1.5 OF POOR shift) DEFECT RATE COST


(PPM) QUALITY (% Sales)

Competitive Level
World Class World Class High Quality Industry Average Industry Average NonCompetitive

6 5 4 3 2 1
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3.4 233 6,210 66,807 3,08,537 6,90,000

< 10% 10%-15% 15%-20% 20%-30% 30%-40% > 40%

Six Sigma Implementation


Five-phases process
1.Establis hing Managem ent Commitm ent 4.Develop ing Monitorin g Systems 5.Busines s 6.Conduc Process ting to Six Be Sigma improved Continuous Projects Improvement are 2.Informat ion Gathering 3.Train ing

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Six Sigma - Three Dimensions


Customer Process A Process B Vendor

Defin e

Measur e

Analyz e

Improv e

Contr ol

Driven by customer needs


Process Map Analysis

Methodol ogy

LSL

US L

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Led by Senior Mgmt


Enabled by quality team.

Organizat ion

Tools

Upper/Lower specification limits

Regression
35 30 25 20 15 100% 80% 60% 40% 20% 0% L K A F B C G R D

Process variation

10 5 0

Frequency

Cumulative Frequency

Pareto Chart

Structured Methods of Six Sigma:


Defi ne

Measure

DMAIC
Control

Analyze

Improve

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DEFINE

Determine Bench mark Set Baseline Determine Customer requirements Get Customer Commitment Map Flow process

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MEASURE

Develop Defect Measurement Develop Data Collection process Collect Data Create Forms Compile and Display Data

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ANALYSE

Verify Data Draw Conclusions From Data Test Conclusions Determine Root Causes

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IMPROVE
v v v v v v v

Create Improvement Ideas Create Models Experiment Set Goals Create Problem Statement Create Solution Statement Implement Improvement Methods

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CONTROL

Monitor Improvement Progress Measure Improvement Statistically Assess Effectiveness Make Needed Adjustments

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Scope of Six Sigma


v v v v v

Manufacturing Service Industries Hospitals Insurance Call Centre

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Table 1: Companies And The Year They Implemented Six Sigma

Company Name Motorola

Year Began Six Sigma 1986

Allied Signal (Merged 1994 With Honeywell in 1999) General Electric's Honeywell Ford
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1995 1998 2000

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THANK YOU