Six Sigma and Lean thinking

Miguel Lopez
M&D Consulting Agency
Agenda
Six Sigma
Introduction
Symbols
Definitions
The k*sigma importance
Example
Organizational levels
Lessons learned
Agenda
Six Sigma
Introduction
Vision
Definitions
Quote
Lessons learned
SIX SIGMA
Introduction Six Sigma
What is a process?
What is Quality Control?
What means to say, a process quality is
in control?
What is a normal distribution?
What is Sigma?
What is a manufacturers specification
limit?
Symbols
Standard deviation =
Average =
Normal distribution = N(,)
Definitions
Sigma is:
The square root of the
variance
What sigma means is
the

o
1
n
i
X
i

( )
2
n

=
Definitions cont.
Normal distribution
= 0
= 1
Blue is N(0,1)
Red is cummulative
N(0,1)
Green, brown, and pink
is 1, 2, and 3
distances respectively
b qnorm .9772490 , 1 , ( ) := b 2 =
c qnorm .998650 , 1 , ( ) := c 3 =
y 0 1 .. :=
4 2 0 2 4
0
0.2
0.4
0.6
0.8
pnorm x 0 , 1 , ( )
dnorm x 0 , 1 , ( )
y
y
y
x x , a , b , c ,
Definition cont.
Specification limit
It is the range of values considered
acceptable in the manufacturing of a
specific product for a specific characteristic.
Six Sigma
To accommodate six times the standard
deviation value in between the
manufacturers specification limits
Definitions cont.
The universal formula
k o +

The k*sigma importance
K Probability ARL nonconforming
1 0.841344746068543 6.30
1.5 0.933192798731142 14.97
2 0.977249868051821 43.96
2.5 0.993790334674224 161.04
3 0.998650101968370 740.80
3.5 0.999767370920966 4,298.69
4 0.999968328758163 31,574.39
4.5 0.999996602326866 294,319.07
5 0.999999713348346 3,488,554.79
5.5 0.999999981010436 52,660,502.10
6 0.999999999013412 1,013,594,634.89
6.5 0.999999999959840 24,900,406,809.35
7 0.999999999998720 781,332,343,402.24
7.5 0.999999999999968 31,383,969,528,714.30
8 0.999999999999999 1,501,199,875,790,170.00
Example
Extrusion of plastic
Assume we are interested in a plastic
extrusion process. We can control the
temperature at which the plastic is melted
and the rate of extrusion.
The manufacturers limits are +/-2mm
The actual situation is represented in the
next slide.
Example cont.
= 0
= 1
USL = 2
LSL = -2
4 2 0 2 4
0
0.2
0.4
0.6
0.8
1
0
pnorm x 0 , 1 , ( )
dnorm x 0 , 1 , ( )
y
y
4 4 x x , LSL , USL ,
Example cont.
What can we do to improve the process?
Reduce the variance thereby reducing
the standard deviation.
How?
Slow the extrusion rate.
Example cont.
4 2 0 2 4
0
0.2
0.4
0.6
0.8
pnorm x 0 , 1 , ( )
dnorm x 0 , 1 , ( )
y
y
x x , LSL , USL ,
4 2 0 2 4
0
0.2
0.4
0.6
0.8
pnorm x 2 , . 5 , ( )
dnorm x 2 , . 5 , ( )
y
y
x x , LSL , USL ,
= 2
= .5
USL = 2
LSL = -2
Example cont.
What can we do to improve the process?
Modify something else
What?
The melting temperature.
How?
A higher temperature.
Example cont.
4 2 0 2 4
0
0.2
0.4
0.6
0.8
pnorm x . 7 , . 5 , ( )
dnorm x . 7 , . 5 , ( )
y
y
x x , LSL , USL ,
4 2 0 2 4
0
0.2
0.4
0.6
0.8
pnorm x 1 , 1.5 , ( )
dnorm x 1 , 1.5 , ( )
y
y
x x , LSL , USL ,
k o +
p p k p + := k
= -1
= 1.5
USL = 2
LSL = -2
Example cont.
Still wrong. What next?
We have to continue trying different
combinations
Ej.
High temperature and high extrusion rate
High temperature and low extrusion rate
Low temperature and high extrusion rate
Low temperature and low extrusion rate
Change the type of plastic
Among others
Example cont.
The answer
should look
in the end
something
like this.
4 2 0 2 4
0
0.2
0.4
0.6
0.8
pnorm x . 7 , . 5 , ( )
dnorm x . 7 , . 5 , ( )
y
y
x x , LSL , USL ,
4 2 0 2 4
0
0.2
0.4
0.6
0.8
pnorm x 0 , . 5 , ( )
dnorm x 0 , . 5 , ( )
y
y
x x , LSL , USL ,
k o +
p p k p + := k
Lessons learned
Six Sigma does not have a unique way
of solving problems in the industry.
It requires experimentation, studies, and good
applied Engineering to solve the problems.
Six Sigma is a tool that if applied correctly the
quality of the product is guaranteed by
showing if non-conforming products are going
to happen or not.
Organizational levels
Since Six Sigma is very famous and it is
one the fashion statements in the industry,
levels have been made to differentiate
how much knowledge a person has in six
sigma
Green belt
Black belt
Master black belt
Organizational levels cont.
Green belt

Black belt
Organizational levels cont.
Master black belt
Lean Thinking
Introduction
What are constraints?
What is efficiency?
What is productivity?
What is added value?
What is cost efficient?
What is lean?
What is thinking?
Vision
Definitions

Quote
Common sense is
the least common
of senses.
Jos Duprey
Lessons learned

QUESTIONS?????