Six sigma essentials

Six sigma essentials

• 1.
  Introduction to SixSigma
• 2.
  Six Sigma originatedas a set of practices designed to improve manufacturing process and eliminate defects but its application was subsequently extended to other types of business process as well In six sigma a defect is defined as any process output that does not meet customer satisfaction
• 3.
  Six Sigma seeksto improve the quality of process outputs by identifying and removing the causes of defects (errors) 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 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)
• 4.
  The term SixSigma originated from terminology associated with manufacturing, specifically terms associated with statistical modeling of manufacturing processes The maturity of a manufacturing process can be described by a sigma rating indicating its yield, or the percentage of defect-free products it creates 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)
• 5.
  Six Sigma doctrineasserts that Continuous efforts to achieve stable and predictable process results (i.e., reduce process variation) are of vital importance to business success. Manufacturing and business processes have characteristics that can be measured, analyzed, improved and controlled. Achieving sustained quality improvement requires commitment from the entire organization, particularly from top-level management.
• 6.
  Six Sigma projectsfollow two project methodologies inspired by Deming's Plan-Do-Check-Act Cycle 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
• 7.
  The DMAIC projectmethodology has five phases  Define the problem, the voice of the customer, and the project goals, specifically.  Measure key aspects of the current process and collect relevant data.  Analyze the data to investigate and verify cause-and-effect relationships. Determine what the relationships are, and attempt to ensure that all factors have been considered. Seek out root cause of the defect under investigation.  Improve or optimize the current process based upon data analysis using techniques such as design of experiments, poka yoke or mistake proofing, and standard work to create a new, future state process. Set up pilot runs to establish process capability.  Control the future state process to ensure that any deviations from target are corrected before they result in defects. Implement control systems such as statistical process control, production boards , visual workplaces, and continuously monitor the process
• 8.
  The DMADV projectmethodology, also known as DFSS ("Design For Six Sigma"),[14] features five phases:  Define design goals that are consistent with customer demands and the enterprise strategy  Measure and identify CTQs (characteristics that are Critical To Quality), product capabilities, production process capability, and risks  Analyze to develop and design alternatives, create a high-level design and evaluate design capability to select the best design  Design details, optimize the design, and plan for design verification. This phase may require simulations  Verify the design, set up pilot runs, implement the production process and hand it over to the process owner(s)
• 9.
  What is SixSigma? A Never Ending Journey To Competitive Leadership By Satisfying Customer Requirements Profitability A Statistical Measure Of A Processes Inherent Ability To Meet Customer Requirements
• 10.
  Six Sigma –Significance 98.930%Good (3.8 Sigma) 99.99966% Good (6 Sigma) 20,000 lost articles of mail per hour Seven articles lost per hour Unsafe drinking water for almost 15 minutes each day One unsafe minute every seven months 5,000 incorrect surgical operations per week 1.7 incorrect operations per week Two short or long landings at most major airports each day One short or long landing every five years 600 new policies per month delivered with errors 1 new policy delivered with errors every 5 months 180,000 lost calls each year 61 lost calls each year No electricity for almost seven hours each month One hour without electricity every 34 years 8/97
• 11.
  The Goal ofSix Sigma – Improving Processes… W hat You Think It Is.. W hat It R eally Is.. W hat It S hould Be... W hat It Could Be...