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Six Sigma:. Production & Operations Management Jonathan Butt Greg Cake Subir Roy July 26, 2005. What is Six Sigma?. Statistically-based process improvement methodology which aims to reduce defects to a rate of 3.4 per million opportunities.
Production & Operations Management
July 26, 2005
Critical to Quality (CTQ): The attributes most important to the customer.
Defect: Failing to deliver what the customer wants.
Process Capability: What your process can deliver.
Variation: What the customer sees & feels.
Stable Operations: Ensuring consistent, predictable processes to improve variation.
Design for Six Sigma (DFSS): Designing to meet customer needs and process capability.
Hospital: 5,000 incorrect surgical procedures per week.
Air travel: Two short or long landings at every major airport every day.
Drug Prescriptions: 200 000 wrong prescriptions every year.
Downtime: 54 hours of system downtime per year.
Golf: One missed putt every nine rounds.
Hospital: 1.7 incorrect surgical procedures per week.
Air travel: a short or long landing at every major airport once every five years.
Drug Prescriptions: 68 wrong prescriptions every year.
Downtime: 2 minutes of system downtime per year.
Golf: One missed putt every 163 years.
This vision included the description of difference competence levels in Six Sigma and based on the traditions of karate, were designated by belts:
In order for a company to be successful in Six Sigma development the following “themes” must become second nature:
Company Size and Percentages with Six Sigma
Note: QD – Quality Digest Magazine, The Dyncorp percentages do not add to 100 because all respondents were used in tabulating results, QD numbers are only respondents who have a six sigma program in place. QD refers to the number of employees as all persons in the employ of the company, Dyncorp does not specify how the number of employee values were determined.
Length of Time Six Sigma Has Been in Place
Note: QD – Quality Digest. QD numbers total 100%, The Dyncorp percentages do not add to 100 because all respondents were used in tabulating results, QD numbers are only respondents who have a six sigma program in place.
Since the Six Sigma philosophy focuses on defects, it would be obvious that it can reduce production times, but six sigma can be used for much more
- Process design: Designed to have the best and most consistent outcome from the beginning.
- Analysis & reasoning: Using facts to find root cause, instead of educated guesses & intuition.
- Focus on process improvement as a key to excellence in quality.
- Broader participation in problem solving.
- Goal setting: aiming at stretch goals, not “good enough” targets. This ensures the company is always striving for improvement.
- Suppliers are no longer evaluated on cost, instead evaluated on relative capability to consistently provide quality materials with short lead times.