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Philosophy of

Six-Sigma

Six sigma is a philosophy of doing any business (providing any product or service) encompassing the methodologies of defect prevention rather than detection. Six sigma uses statistical tools that can vary from Pareto chart to designed experiments. It provides a foundation for continuous improvement and world class improvement efforts. Products could be any goods or service and continuous improvement would cover quality, costs, speed, productivity and customer satisfaction

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Customers Perspective of Six-Sigma

CUSTOMER Meeting or exceeding customer requirements to achieve customer satisfaction is the most acceptable way to define quality today. This definition, however is more appropriately the fundamental objective. PROCESSES Process management includes the continuous study of the relationship between variations and outputs and sources of variation which may be present in the process. Statistical tools provide a way to study the process and effect of sources of variation.

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SIX-SIGMA
Concept of Six-Sigma Quality
An approach to measuring and improving product and services quality addressing cost, quality, productivity, delivery times and customer satisfaction resulting in beefed up bottom lines

Realization of many fundamentals of Total Quality Management notably the integration of human and process elements of improvement. Only one ultimate goal- Zero Defect It does not matter how rare the disease is. If you have got it, thats all that matters Understanding of a management strategy and its deployment down the lines and how it can transform the organization.

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SIX-SIGMA Quality
Originally conceived by Motorola in 87 and later successfully used by Boeing, Caterpillar, Corning Digital Equipment, IBM, Raytheon, Whirlpool & GE

The name is derived from the fact that the specification limits are six process-standard deviation away from the targeted midpoint of the tolerance range

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Six-sigma ..The numeric significance

-1.5 +1.5

3.4 PPM

-3

Mean 0

+3

Process Variability

-6

+6

Mean Level 1.5 off center

3 sigma 66,803

4 sigma 6200

5 sigma 233

6 sigma 3.4

SIX-SIGMA represents 3.4 defects per million opportunities

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SIX-SIGMA
DMAIC Model

Implementation

Recognized benchmark for six-sigma implementation is General Electric It employs following five phases;

1. Define (D)
- Identify customers and their priorities - Identify a project suitable for six-sigma based on business objectives as well as customers need and feedback. - Identify CTQs ( critical to quality characteristics) that the customer considers to have the most impact on quality

2. Measure (M)
- Determine how to measure the process and how is it performing - Identify the key internal processes that influence the CTQs and measure the defects currently generated relative to those processes

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SIX-SIGMA
3. Analyze (A)

Implementation (contd.)

- Determine the most common cause of defect - Understand why defects are generated by identifying the key variables that are most likely to create process variations

4. Improve (I)
- Identify means to remove the causes of the defects - Confirm the key variables and quantify their effect on the CTQs. - Identify maximum acceptable range of the key variables and system to measure deviations of the variables - Modify the process to stay within the acceptable range.

5. Control (C)
- Determine how to maintain the improvements - Put tools in place to ensure that the key variables remain within the maximum acceptable range under the modified process. .. The approach appears to be similar to other quality improvement approaches. The key difference is the emphasis on customer requirements and aggressive use of advanced statistical tools and methodologies.

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Design of Experiments
DOE In using SPC tools, we constantly strive for reducing variation. This is done by detecting and reducing un-expected variation (Significant Events). Most SPC tools are passive in their approach in identifying opportunities for improvements. Essentially the way we learn from basic SPC tools i.e) to increase the opportunity to see a significant event. Control charts can be very effective at increasing the chances of observing a significant event, but if not properly, it may just as likely hide significant events (eg: improper sampling). To over simplicity, Basic SPC tools and techniques wait for an event to happen and help you observe it. This passive method of detaining knowledge will not be enough to allow us to compete in future.

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Design of Experiments

(DOE)

Improved observation.. .ensures that naturally occurring informative events are brought to the notice of perceptive observers and increase the probability of observing naturally occurring informative events so that appropriate actions can be taken.

UCL

Mean

LCL

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Design of Experiments

(DOE)

Induction of Occurrence of informative events

An EXPERIMENT is an invitation for an informative event to occur. The manipulation of controllable factors (INDEPENDENT VARIABLE) at different levels to see their effect on same response (DEPENDENT VARIABLE)

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Design of Experiments

(DOE)

COMMON METHODS
Trial and error One factor at a time Full factorial Fractional factorial Others

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TRIAL AND ERROR

Problem Mileage of car is 20 kmpl Would like to get>30kmpl

Solution thought of Change the petrol octane Change the brand of petrol Change petrol pump Drive slow Tune up car Wash and wax car New tyres Change tyre pressure Take up body wt reduction program at home What if it works? What if it doesnt?

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OFAT
Speed
55 65 55 55

Mileage
25 23 27 27

Octane
85 85 91 85

Tyre Pr.
30 30 30 35

How many runs? Is it realistic if co variable What if there is a co-relation between factors? Problem Time and money Noise in data Unrealistic in factory environment

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FULL FACTORIAL
An experimental strategy that allows us to answer questions most completely. Full factorials examine every possible combination of factors at the levels tested. The enable us to: Determine main effects of the factors manipulated as selected response variables. Determine effects of factor evaluation as selected response variables. Determine levels to set factors for best results.

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PROBLEM : Mileage is 20, Would like to get > 30.

SPEED (A) 55 65 55 65 55 65 55 65 OCTANE (B) 85 85 91 91 85 85 91 91 TYRE PRESS MILEAGE (Y) (C) 30 30 30 30 35 35 35 35 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8

How many runs? How many observations at each level?

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COMPARISON OF METHODS
There are many methods of experimentation. Some method such as trial and error is deficient and will not facilitate an increase in knowledge. Other methods such as OFAT are inefficient and may lead to error on conclusion Statistically designed experiments are efficient procedure for discovering relationship between independent factors (process parameters), such as temperature, pressure, time, speed etc and response variable (Product Parameter)such as size, variation , ductility, shrinkage etc The independent factors are varied in specific fashion and the effect of these changes on the response is measured. The fashion in which two independent variables are manipulated may be thought of as the experimental design.

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LIMITATIONS OF FULL FACTORIAL

The limitations are not in theory but in practicality. The resources (i.e. time & cost) necessary to run full factorial designs can be significant. Full factorials can be used when investigating a small number of variables (2-4), but are not recommended when investigating a large number of factors (5 or more). The number of runs needed increase exponentially with the number of factors, making the costs involved prohibitive. This does not means that full factorials are not useful, but they are to be used at the proper time.

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LEVELS OF EXPERIMENTS IN

FULL FACTORIAL
SYMBOL EXPERIMENTS

FACTORS

LEVELS

2
3 7 15 2

2
2 2 2 3

2^2
2^3 2^7 2^15 3^2

4
8 128 32,768 9

3
7

3
3

3^3
3^7

27
2,187

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FRACTIONAL FACTORIAL
A Fractional Factorial as it sounds, looks at only fractional of all the possible combination contained in full factorial. Therefore, if there are many factors being investigated, information can be obtained with much less investment. It is the Fractional factorial that has significantly increased the use of experimentation throughout the world. The resources required to complete a fractional factorial are manageable and not much relevant information is given up. The success is proven.

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PROBLEM: Mileage is 20 Required is > 30

SPEED (A) 55 65 55 65

OCTANE (B) 85 85 91 91

TYRE PRESS. (C)

MILEAGE (Y) Y1 Y2 Y3 Y4

35 30 30 35

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FRACTIONAL FACTORIAL ( CONTD.)

OBSERVATIONS
How Many Runs? How Much Information? Is there a balance?

LIMITATIONS
Give up some information Inexperience in Use Fear of Statistics HENCE WE NEED A SYSTEMATIC EXPERIMENT STRATEGY FOR LOOKING AT MANY FACTORS AT THE SAME TIME

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Other Methods of Experimentation

STANDARD ORDER DESIGN (2^n)
also called Yates order.manipulates main effects

RANDOMIZATION
. Allows equal opportunity for an event to occur . Usually impractical

RUN ORDER
.. Brings about an order in randomization

ROSSES RULES OF ANALYSIS

.. Practical importance consideration

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SIX-SIGMA
Leadership/ Sponsorship

The organization

Leadership system, top level commitment, deployment involvement, training , reward & recognition system

Champion
Fully trained business leaders who promote, sponsor & support the improvement projects

Master Black belts

Fully trained quality leaders responsible for six-sigma projects strategy, training, mentoring, deployment & Results

Black Belts
Fully trained six-sigma experts who lead the projects, ensure results and mentor the green belts

Green Belts
Black belts in making & working with black belts.

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SIX-SIGMA

some things to remember

Real power comes when you are able to combine people power with process power Everyone can see clearly what he/she can do better Six-sigma does not teach the art of managing a problem but the science of eliminating the problem The front liners see and hear things that guys in the offices dont. Cost of training people is a very small percentage of what trained, developed & motivated workforce can get you back. Pick the one that hurts you the most. If you can fix it , fix it. And it will reward you the most. You would have lot more credibility with your people if you could back up what you say, with figures. Six-sigma is not doing it better. It is eliminate the bad Two ways of winning. Spectacular Performance Or Fewer Mistakes