Académique Documents
Professionnel Documents
Culture Documents
8
Six Sigma Quality (Continued)
Number of defects
DPMO = x 1,000,000
ª Number of º
« opportunities »
« for error per » x No. of units
« unit »
¬ ¼
9
k-Sigma Quality Levels
10
Six-Sigma Implementation
z Emphasize dpmo as a standard metric
z Provide extensive training
z Focus on on corporate sponsor support
z Create qualified process improvement
experts
z Ensure identification of appropriate metrics
z Set stretch objectives
11
Six-Sigma Problem Solving Approach
(DMAIC Cycle)
12
7 Tools for TQM and Continuous Improvement:
Tool #1: Flow Chart
Material No,
Received Continue…
Inspect
from
Material for Defects
Supplier
Defects found?
Yes
A Flowchart Can be
used to find quality Return to
problems Supplier
for Credit
13
Tool #2: Run Chart
Can be used to identify
when equipment or
processes are not
behaving according to
0.58 specifications
0.56
0.54
Diameter
0.52
0.5
0.48
0.46
0.44
1 2 3 4 5 6 7 8 9 10 11 12
Time (Hours) 14
Tool #3: Pareto Analysis
to find when
80% of the
problems
may be
attributed to
Frequency
20% of the
causes
Wrong Account
Wrong Amount
A/R Errors
Wrong Account
Wrong Amount
16
Tool #5: Histogram
Number of Lots
0 1 2 3 4 Defects
Data Ranges in lot
17
Tool #6: Cause & Effect Diagram
Environment Effect
Method Material
1020
UCL
1010
1000
990
980
LCL
970
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
19
Six Sigma Belts
z Team Member
– Support project within work area
z Green Belt
– 10 days training
– Project with demonstrated improvement
– Training, mentoring team members
z Black Belt
– 4 weeks training
– Project
– Lead improvement teams across business, mentor green belts
z Master Black Belt
z Champions
20
Black Belt Training
z Elementary statistics
z Advanced statistics
– DOE, ANOVA, Multivariate Regression
z Product design and reliability
– QFD, FMEA
z Measurement
– Process Capability
z Process control
– Control Plans and SPC
z Process improvement
– Process improvement planning, process mapping, poka-yoke
z Implementation and teamwork
– Organizational effectiveness, team assessment, facilitation tools,
team development
21
Additional Six Sigma Tools:
z Opportunity Flow Diagram used to graphically
show those activities that add value from those
that are performed (and maybe could be reduced or
removed) that do not add value to the finished
product
27
FMEA
29
FMEA Form
30
Six Sigma Mini Case - NISSAN MOTOR COMPANY
Logo keeps
falling off!
Level
Factor
High Low
Adhesion Area (cm2) 15 20
Type of Glue Acryl Urethan
Thickness of Foam Styrene Thick Thin
Thickness of Logo Thick Thin
Amount of pressure Short Long
Pressure application time Small Big
Primer applied Yes No
33
)DFWRU(IIHFW3ORW
6.5
5.58 5.65 5.58
5.5 5.43 5
4.6
- - - -
34