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Understanding Variation
When the Lord created the world and people to live in it - an enterprise which,
according to modern science, took a very long time – I could well imagine that
he reasoned with himself as follows:
“If I make everything predictable, these human beings, whom I have endowed
with pretty good brains, will undoubtedly learn to predict everything,
because they will recognize that the future is totally determined and cannot be
influenced by any human action.
Understanding Variation
they will gradually discover that there is no rational basis for any decision
whatsoever and, as in the first case, they will thereupon have no motive to do
anything at all.
They will then, amongst many other things, have the very important task of
finding out which is which.
Understanding Variation
11 161 11 121 i- 1
s=
12 194 44 1936 Standard Deviation
n- 1
13 171 21 441
14 125 –25 625
15 163 13 169 n
(X - X )
2
i
Sum 2250 9128
n
(X - X )
2
Mean 150
i
i- 1
n- 1
S2 652
S1 25.53
n
(X - X )
2
i
i- 1
n- 1
Understanding Variation
If we take the height of all the people of India and draw a distribution
Of frequencies it will tend to follow a normal distribution
Understanding Variation
Mean
X-bar
Understanding Variation
Mean
X-bar LSL
USL
LSL and USL are those specification limits beyond which your product
doesn’t have a salable value in the market
Understanding Variation
Mean
X-bar USL
LSL
T
Cp = T/6σ
Cpk = {(Mean - LSL)/3σ ,(USL - Mean)/3σ }
Understanding Variation
34.13% 34.13%
13.60% 13.60%
2.14% 2.14%
0.13% 0.13%
95.46%
99.73%
SIGMA
68.26% Fall Within +\- 1 Sigma
95.46% Fall Within +\- 2 Sigma
99.73% Fall Within +\- 3 Sigma
Understanding Variation
y
1SD= 68% DATA
3SD = 99%DATA
0
x
Understanding Variation
Always Present
Common Cause Expected
Predictable
Normal
6 σ process
Process Width
Cp = Specification width
Process Width
Process variability
SPECIFICATION WIDTH
If the variability is well within the specified width then the process is capable
3-Sigma VS 6-Sigma Process
In every process it is observed that 1.5 Sigma long term drift takes place
-6 -5 -3 -2 -1 0 1 2 3 4 5 6 -6 -5 -3 -2 -1 0 1 2 3 4 5 6
Z- Scale 66,807 DPMO 3.4 DPMO
Z- Scale
3-Sigma Process 6-Sigma Process
What is Six Sigma ?
Percent DPMO
93% 66,807 3.0
98% 22,750 3.5
99% 6,210 4.0
99.87% 1,350 4.5
99.9997% 3.4 6.0
Understanding Variation
Benchmarking
IRS - Tax Advice (phone-in)
100K
(66810 ppm)
Restaurant Bills
Doctor Prescription Writing
10K Payroll Processing
Order Write-up
Average Journal Vouchers
Wire Transfers
Company(6210 ppm)
1K
Purchased Material
Lot Reject Rate Air Line Baggage
Handling
(233 ppm)
100
10
Best in Class
Domestic Airline
(3.4 ppm)
Flight Fatality Rate
1
2 3 4 5 6 (0.43 ppm)
7
SIGMA (with ±1.5 Sigma Shift)
Understanding Variation
Sweet Fruit – 6
Design for Six Sigma (DFSS) DFSS
Process Entitlement
Bulk of Fruit – 4 to 5
Process Improvement Six
Sigma Tools
DMAIC
Ground Fruit – Up to 2
Logic and Intuition +
Basic Quality Tools
Kano Model
Satisfaction
+
Delighters
Innovation One-Dimensional
Competitive Priority
Dysfunctional Functional
Must Be
Critical Priority
–
Dissatisfaction
Taguchi Model
Cost
Performance
Six Sigma
Customer Happy
The methodology:
DMAIC
(define, measure, analyse, improve, control)
methodology to root out and eliminate the causes of defects
Methodology
Process
Scatter Plots Regression DOE
Pilot
Wk 1 Wk 2 Wk 3 Wk 4 Wk 5 Wk 6 Wk 7 Wk 8 Wk 9 Wk 10 Wk 11 Wk 12
A
B
C
D
E
F
G
H
I Documenting Response Plan
J
Induce Statistical thinking
Practical problem
Statistical problem
Statistical solution
Practical solution
DMAIC Methodology
Charter A Team
Process Variation
Define
Clarify Customer Requirements
Root Cause
Analysis
Generate
Improve
Solutions
Select
Pilot
Implement
Control
Do 4 Solution Improve
Planning And
Implementation
Check 5 Confirming
Solution Works
6 Standardization Control
Deliverables
Deliverables
Deliverables
Deliverables
Deliverables
Quality Leader/Six
Champion/Sponsor Sigma Coordinator
External
Master Black Belt Consultant