SIX SIGMA

By

Amanpreet Kaur

What is Six Sigma?

A statistical concept that measures a process in terms of defects A methodology and a symbol of quality Is a process in which 99.99966% of the products manufactured are statistically expected to be free of defects (3.4 defects per million).

Six Sigma seeks to improve the quality of process outputs by identifying and removing the causes of defects and minimizing variability in manufacturing and business processes . It uses a set of quality management methods, including statistical methods, and creates a special infrastructure of people within the organization ("Black Belts", "Green Belts", etc.) who are experts in these methods.

Sigma Level
Sigma Level (Process Capability) 2 3 Defects per million opportunity 308,537 66,807

4
5 6

6,210
233 3.4

Six sigma = 99.9997%

Why Six Sigma?

Cost Quality

Customer Satisfaction

Competitive Advantage

Growth

Employee Pride

Why Six Sigma?

At GE, Six Sigma added more than $ 2 billion to the bottom line in 1999 alone Motorola saved more than $ 15 billion in the first 10years of its Six Sigma effort years Honeywell (Allied Signal) reports saving $ 15 billion through Six Sigma

Methods of Six Sigma Project

DMAIC is used for projects aimed at improving an existing business process. DMADV is used for projects aimed at creating new product or process designs

DMAIC
Define Measure Analyze Improve Control
1. Define the problem, the voice of the customer, and the project goals, specifically. 2. Measure key aspects of the current process and collect relevant data. 3. Analyze the root causes of the defects

4. Improve or optimize the current process based upon data analysis using techniques
5. Control the future state process to ensure that any deviations from target are corrected before they result in defects.

DMADV or DFSS
Define Measure Analyze Design Verify 1. Define design goals that are consistent with customer demands and the enterprise strategy. 2. Measure and identify CTQs (characteristics that are Critical To Quality), product capabilities, production process capability and risks. 3. Analyze to develop and design alternatives, create a high-level design and evaluate design capability to select the best design.

4. Design details, optimize the design, and plan for design verification. This phase may require simulations.
5. Verify the design, set up pilot runs, implement the production process and hand it over to the process owner(s).

Tools for Six Sigma

Process Mapping - A process map is illustrated description of how a process work Design of Experiment - structured, organized method for determining the relationship between factors (X) affecting a process and the output of that process (Y)

XY Matrix - The XY matrix allows the team to identify gaps, areas for improvement

Process capability tool - Process capability tool is the measure of a process being able to meet specification requirements and fulfill customer CTQ needs on a long term basis Hypothesis testing - Investigating a theory about the suspected cause (s) of a particular effect in a process to determine if it is correct. Control Plan - It ensures that all your analysis and efforts stay in effect and that you have information at your disposal.

Failure Mode and Effect Analysis - The manner in which a part or process can fail to meet a specification, creating a defect or nonconformance, and the impact on the customer if that failure mode is not prevented or corrected. Other tools Regression Analysis, histograms, scatter diagrams, chi- squared test ,etc.

Key Roles for Six Sigma

Executive Leadership includes the CEO and other members of top management Champions take responsibility for Six Sigma implementation across the organization in an integrated manner. Master Black Belts act as in-house coaches on Six Sigma; devote 100% of their time to six sigma; assist champions and guide black belts Black Belts operate under Master Black Belts to apply Six Sigma methodology to specific projects Green Belts are the employees who take up Six Sigma implementation along with their other job responsibilities

Application
Manufacturing Pharmaceutical industry Airline industry Healthcare Hospitality services

Some of the companies successfully adopted six sigma strategies include

Thank you