Six-Sigma Quality

z Ensuring that process variation is half the

design tolerance (Cp = 2.0) while allowing the
mean to shift as much as 1.5 standard
deviations.

8
Six Sigma Quality (Continued)

z Six Sigma allows managers to readily describe

process performance using a common metric:
Defects Per Million Opportunities (DPMO)

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)

1. Define (D) Customers and their priorities

2. Measure (M) Process and its performance

3. Analyze (A) Causes of defects

4. Improve (I) Remove causes of defects

5. Control (C) Maintain quality

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

Can be used 80%

to find when
80% of the
problems
may be
attributed to

Frequency
20% of the
causes

Design Assy. Purch. Training Other

Instruct.
15
Tool #4: Checksheet

Can be used to keep track of

defects or used to make sure
people collect data in a
Monday correct manner
Billing Errors

Wrong Account

Wrong Amount

A/R Errors

Wrong Account

Wrong Amount

16
Tool #5: Histogram

Can be used to identify the frequency of quality

defect occurrence and display quality
performance

Number of Lots
0 1 2 3 4 Defects
Data Ranges in lot
17
Tool #6: Cause & Effect Diagram

Possible causes: The results

or effect
Machine Man

Environment Effect

Method Material

Can be used to systematically track backwards to

find a possible cause of a quality problem (or
effect)
18
 Tool #7: Control Charts (SPC)

Can be used to monitor ongoing production process

quality and quality conformance to stated standards of
quality

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

z Failure Mode and Effect Analysis (FMEA) is a

structured approach to identify, estimate, prioritize,
and evaluate risk of possible failures at each stage
in the process

z Design of Experiments (DOE) a statistical test to

determine cause-and-effect relationships between
process variables and output

27
FMEA

z Technique used to determine what chronic

failures are occurring in a product or
manufacturing/assembly process and the
likely impact and frequency

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

- - - -

Adhesion Thk of Foam Thk of logo

Area Type of Glue
Styrene

34