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SIX SIGMA QUALITY TECHNIQUES...

SIX SIGMA QUALITY TECHNIQUES. WHERE YOU NEED TO BE TO COMPETE IN THE NEW MILLENNIUM. Michael W. Piczak Dipl.T., B.Comm., MBA. THE MAIN ELEMENTS. DE FACTO, 6 SIGMA IS: . The search for and control of X’ s. GOALS OF 6 SIGMA. Defect reduction Yield improvement Improved customer satisfaction

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SIX SIGMA QUALITY TECHNIQUES...

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  1. SIX SIGMA QUALITY TECHNIQUES... WHERE YOU NEED TO BE TO COMPETE IN THE NEW MILLENNIUM Michael W. Piczak Dipl.T., B.Comm., MBA

  2. THE MAIN ELEMENTS

  3. DE FACTO, 6 SIGMA IS: The search for and control of X’s

  4. GOALS OF 6 SIGMA • Defect reduction • Yield improvement • Improved customer satisfaction • Higher net income

  5. WHERE TO FOCUS? For each product or process critical to quality (CTQ): • Measure • Analyze • Improve • Control

  6. PRIMARY SOURCES OF VARIATION • Inadequate design margin • Unstable parts and material • Insufficient process capability

  7. WHO IS THE ENEMY? VARIATION

  8. RECOGNITION OF & STATEMENT OF PROBLEM CHOICE OF FACTORS (Xi’s), LEVELS, RANGES SELECTION OF RESPONSE VARIABLE (Y) CHOICE OF EXPERIMENTAL DESIGN PERFORMING EXPERIMENT STATISTICAL ANALYSIS OF DATA CONCLUSIONS, RECOMMENDATIONS, NEXT STEPS

  9. OUR BASIC RESEARCH PARADIGM • Enter data and editing same • Verify data integrity via Counts/Describe • Run Descriptives • Generate graphs & charts of data • Analyze ANOVAs • Run regressions, DOEs, GR&Rs

  10. PEDAGOGICAL APPROACH • Lecture • Discussion, debate and argument • Videos • Hands-on exercises using general and company specific examples

  11. TERMINAL PERFORMANCE OBJECTIVES As a result of taking this program, the participant will be able to: • Appreciate the scope of 6 Sigma practices in context of other company initiatives • Apply a variety of tools to solve problems

  12. T.P.O.s CONTINUED... • Participate as a contributing member of a continuous improvement or problem solving team • Use Minitab as a data analysis tool

  13. GENESIS OF 6 SIGMA

  14. WHAT ARE WE REACHING FOR?

  15. ELEMENT 1

  16. PORTER’S 5 FORCES MODEL

  17. PEST MODEL

  18. ‘BONUS’ MODEL A key element

  19. VOICE OF THE CUSTOMER • 2 Brands of customers • internal • external

  20. ALL ON THE SAME PAGE Voice of the customer

  21. DESCRIBE THE PROCESS

  22. IMPROVING THE PROCESS • Elimination • Simplification • Combination • Reuse • Parallel processing • Subcontracting

  23. CRITICAL EXAMINATION

  24. NO NEW PROBLEMS PLEASE • Poka Yoke techniques • guide pins • templates • limit switches • limited computer screen fields • checklists • interconnects

  25. GETTING BETTER? • The need to measure in quantitative terms important • QS9000 demands it in terms of quality and effectiveness • customer satisfaction • quality levels (# non-conformances, dpu, dpmo) • cycle times • die change times

  26. ELEMENT 2: MEASUREMENT

  27. OLD METRICS • Measures of central tendency or typicality (mean, median, mode) • Measures of dispersion (range, variance, standard deviation)

  28. THE NORMAL DISTRIBUTION

  29. NORMAL CURVE CHARACTERISTICS • Continuous • Symmetrical • Tails asymptotic to zero • Bell shaped • Mean = median = mode • Total area under curve = 1

  30. A KEY FORMULA

  31. VARIATION IN PERSPECTIVE • ± 1 Sigma • ± 2 Sigma • ± 3 Sigma • ± 4 Sigma • ± 5 Sigma • ± 6 Sigma • ± ? Sigma

  32. VISUALIZING VARIATION

  33. THE HUNT FOR X

  34. FIXING BELIEF • Method of tenacity • Method of authority • Method of reasoning • Method of science

  35. THE SCIENTIFIC METHOD

  36. VISUALIZING VARIATION

  37. PROCESS CAPABILITY

  38. PROCESS CAPABILITY II

  39. THE JOURNEY • Most companies presently at 3-4 sigma • The move is toward 6 sigma (Cp = 2) • Literature has references to 12 sigma (Cp = ?)

  40. Cpk

  41. HYDRAULIC LIFT COMPANY See case on Page 37

  42. CAPABILITY ST & LT

  43. Cp LONG TERM (LT)

  44. ST to LT

  45. NEW METRICS • dpu • dmpo THE CAVEAT

  46. Dpmo, Cp and Sigma • using page 608 Lindsay and Evans, derive figures shown • using page 48 Piczak, derive figures shown

  47. 2 ROADS TO PROFITABILITY

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