Six Sigma Primer - APICS-San Gabriel Valley Chapter

40 Pages·2012·1.95 MB·English

Six Sigma Primer
Seeking Meaningful Improvements
Presented by: Andy Pattantyus
Prepared for:
APICS San Gabriel Valley Chapter
by
Strategic Modularity, Inc.
www.strategicmodularity.com
[email protected]
Phone: 855-LeanOps FAX: [phone]
April 18, 2012 © Strategic Modularity Inc. 2012 www.strategicmodularity.com Page 1 of 40
Six Sigma Primer
Learning Objectives
• What is six sigma?
• Are my processes six sigma?
• What is process capability?
• Why care about six sigma?
• How can I get a process to six sigma?
• The six sigma goal: improving yield
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1. What is Six Sigma?
Overview
• A description of process capability
– Statistical
– Mathematical
• An operational philosophy
– CPI – Continuous Process Improvement
– VR&C – Variability Reduction & Control
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What is Six Sigma?
Definitions - ASQ
• Six Sigma is a philosophy
– This perspective views all work as processes that can be defined,
measured, analyzed, improved and controlled. Processes require inputs (x)
and produce outputs (y). If you control the inputs, you will control the
outputs: This is generally expressed as y = f(x).
• Six Sigma is a set of tools
– The Six Sigma expert uses qualitative and quantitative techniques to drive
process improvement. A few such tools include statistical process control
(SPC), control charts, failure mode and effects analysis and flowcharting.
• Six Sigma is a methodology
– This view of Six Sigma recognizes the underlying and rigorous approach
known as DMAIC (define, measure, analyze, improve and control). DMAIC
defines the steps a Six Sigma practitioner is expected to follow, starting
with identifying the problem and ending with the implementation of long-
lasting solutions. While DMAIC is not the only Six Sigma methodology in
use, it is certainly the most widely adopted and recognized.
Source: ASQ [1]
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What is Six Sigma?
Definitions – Lean Lexicon
• A quality standard of just 3.4 defects per one million
opportunities; 99.9996% perfect.
• Six sigma methodologies emphasize mathematical and
statistical tools to improve the quality of processes that are
already under control.
• Application follows a five-step process of define, measure,
analyze, improve, and control often referred to as DMAIC.
• The term refers to the number of standard deviations a point is
away from the mean point in a bell curve. It often is
represented as 6 sigma.
Source: Lean Lexicon [2]
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What is Six Sigma?
History
• Born at Motorola
– Motorola conceived the six sigma technique in
1986 as a way to achieve the company’s
improvement goals in manufacturing and support
functions.
• Motorola Suppliers – Starting 1991
– Eveready Battery Company Inc. (Energizer)
• Early corporate adopters – Starting 1995
– Allied-Signal (now Honeywell)
– General Electric
– 3M
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What is Six Sigma?
Mathematics or Management?
• Mathematics
– Field of statistics known as Process Capability
– Basis for measurements
– Verifiable data is the basis for decisions
• Management
– Continuous improvement efforts
• Reduce process variation
• Achieve stable and predictable results
– Focus on business and manufacturing processes
– Organizational commitment, especially top-level
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2. Are my processes six sigma?
Probably Not!
• If your organization knows process
capability, and regularly uses it as a
tool, then you know if your processes
are six sigma.
• Otherwise, most processes which have
not been the object of continuous
process improvement and variability
reduction are likely less than 4 sigma.
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3. Process Capability
A qualitative definition
• Capable Process - Predictable
– Stays in control w/o intervention
– Get it right the first time
– Process monitoring: Good Process = Good part
– High yield
• Poor Process - Unpredictable
– Out of control - constant intervention required
– High Scrap and/or Lots of rework
– Checking parts instead of monitoring processes
– Low yield
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Process Capability - Cp
A quantitative definition
SpecificationWidth
Cp =
ProcessCapability
±6σ
Cp = ±4σ Cp =1.33 Cp = Cp = 2.0
±3σ
±3σ
Source: Motorola [4]
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