6 s. 6Sigma Program & Concepts Overview. Control. Project Phases:. Presenters: P. Pfaff H. Myrie K. Barker. Improve. Analyze. Measure. 6 s. Meet Larry. Larry is a golfer. His play is, shall we say, erratic? He wants to play more consistently. 6Sigma Example  Measure Phase.
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6s
Control
Project Phases:
Presenters:
P. Pfaff
H. Myrie
K. Barker
Improve
Analyze
Measure
6s
Meet Larry.
Larry is a golfer.
His play is,
shall we say,
erratic?
He wants to play
more consistently.
Larry’s Golf Game
Specification: Larry wants to shoot between 80 and 100 this season, with a target average score of 90.
Cpk = 0.05 !!!
capability?
*(Best Process Cp  Sources of Variation Eliminated)
Cp = 1.88
Larry is Here
3.0
Improve
Control
Control (Zshift)
1.5
Goal
ZST = 5.64
ZLT = 0.15
ZSHIFT = 5.79
(ZSHIFT = ZST  ZLT)
Improve
Skills
0
0
3.0
6.0
Technology/Skills (ZST)
1
0
0
1
0
0
0
8
0
t
n
u
o
C
5
0
0
4
0
2
0
0
0
t
r
g
o
n
S
h
o
t
T
y
p
e
h
o
S
L
7
7
7
4
7
0
C
o
u
n
t
P
e
r
c
e
n
t
6
2
.
3
3
7
.
7
6
2
.
3
1
0
0
.
0
C
u
m
%
6Sigma Example  Measure PhaseLet’s analyze his game by breaking down his score.
Where is the biggest opportunity in his overall game?
He takes more shots
in his short game (62.3%).
8
0
0
1
0
0
7
0
0
8
0
6
0
0
t
5
0
0
n
u
4
0
0
o
C
4
0
3
0
0
2
0
0
2
0
1
0
0
0
0
s
s
p
t
t
i
S
h
o
t
T
y
p
e
u
h
P
C
C
o
u
n
t
5
2
0
2
5
7
P
e
r
c
e
n
t
6
6
.
9
3
3
.
1
C
u
m
%
6
6
.
9
1
0
0
.
0
6Sigma Example  Measure PhaseLet’s continue analyzing his game by breaking it down further.
Where is the biggest opportunity in his short game?
He takes more shots
in his putting game (66.9%).
Cause & Effect Diagram  Larry’s Putting Game
Measurement
Material
Larry
Putting Score
Environment
Methods
Machine
6s
Control
Project Phases:
Presenters:
P. Pfaff
H. Myrie
K. Barker
Improve
Analyze
Measure
Cause & Effect Diagram  Larry’s Putting Game
Measurement
Material
Larry
>Cheat at Counting
> Can’t Remember
> Pencil has an eraser
> Grass Type
>Number of Drinks
> Eye Glasses Prescription Updated
> Properly Rested
Putting Score
> Golf Course
> Green Condition
> Time of Day
> Weather
> Playing Partners
> Betting of Hole
> Putting Style
 Stance
Grip
 Swing
> Reading the Green
>Putter Type
> Ball Type
> Shoes
> Glove
Environment
Methods
Machine
Is putting really a significant source of variation in the overall golf score?
ScatterPlot/Fitted Line Regression
1
3
0
Yes!!!
1
2
0
e
1
1
0
r
o
c
S
Y
=
3
3
.
1
2
8
4
+
1
.
6
7
5
4
6
X
1
0
0
RSquared = 0.906
9
0
The RSquared value says
that 90.6% of the variation
in the Overall Score is
directly related to the
putting game.
3
5
4
0
4
5
5
0
P
u
t
t
s
Let’s figure out what is causing the variation in his putting game. . .
What did Larry do
differently during
this time frame?
If he gave up drinking, does the number of drinks directly affect his putting?
ScatterPlot/Fitted Line Regression
5
4
Yes!!!
s
4
4
t
t
u
P
Y
=
3
6
.
2
5
+
2
X
RSquared = 0.872
3
4
The RSquared value says
that 87.2% of the variation
in Putting is directly related
to the number of drinks he had.
0
1
2
3
4
5
6
D
r
i
n
k
s
Conclusions
6s
Control
Project Phases:
Presenters:
P. Pfaff
H. Myrie
K. Barker
Improve
Analyze
Measure
Cause & Effect Diagram  Larry’s Putting Game
Measurement
Material
Larry
>Cheat at Counting
> Can’t Remember
> Pencil has an eraser
> Grass Type
>NUMBER OF DRINKS
> Eye Glasses Prescription Updated
> Properly Rested
Putting Score
> Golf Course
> Green Condition
> Time of Day
> Weather
> Playing Partners
> Betting of Hole
> Putting Style
 Stance
Grip
 Swing
> Reading the Green
>Putter Type
> Ball Type
> Shoes
> Glove
Environment
Methods
Machine
In order to improve his game above the 5sigma level he has to improve his skills.
This is the Experiment Matrix that they decided to run!
This is a 23 DOE, which has eight conditions to test.
This is the Experiment Matrix after we randomized
the order that they will run!
Randomization is done to detect
the effect of other noncontrolled variables.
We ran the experiments and these are the results.
p = .003
Interaction Plots for Putting Score
Main Effects Plot for Putting Score
1
1

1
1
1
40
38
36
34
32
Open Stance
Open Stance
p = .026
p = .873
p = .037
Stance

1

1
Putting Score
Close Stance
40
38
36
34
32
Close Stance

1
40
38
36
34
32

1
1
Old Reliable
1
Putter
Type
Big Bubba
Old Reliable

1
1
Big Bubba
1
Open
Interlock
Stance
Putter
Type
Open
Open
Grip
Grip
Close
Interlock
Big Bubba
Old Reliable
The Closed Stance with the Interlocked Grip gives Larry the Lowest Score!
(Verified statistically.)
Stance and Grip are significant factors.
(Verified statistically.)
DOE Conclusions
6Sigma Example  Improve Phase
So, What is Larry’s Improvement Plan?
Measure
6Sigma Example  Improve Phase
Has Larry
improved?
USL
LSL
Yes! How much?
From Measure:
Zlt = 0.15 DPMO = 820,000
Zst = 5.64
From Improve:
Zlt = 4.23 DPMO = 12
6s
Control
Project Phases:
Presenters:
P. Pfaff
H. Myrie
K. Barker
Improve
Analyze
Measure
Remember Larry’s Improve “Plan” . . .
. . . and the Results
From Measure:
Zlt = 0.15 DPMO = 820,000
Zst = 5.64
From Improve:
Zlt = 4.23 DPMO = 12
6Sigma Example  Control Phase
Larry Needs a Control Plan
6Sigma Example  Control Phase
So, What is Larry’s Control Plan?
Mistake  proofing
More of Larry’s Control Plan
Okay, he’s got a plan.
Is there any risk associated with it?
Risk Assessment
Giving up drinking is a risk!
Need an Abatement Plan
Abatement Planning
If he drinks moderately,
can he maintain an improvement?
ScatterPlot/Fitted Line Regression
5
4
s
4
4
t
t
u
P
Y
=
3
6
.
2
5
+
2
X
RSquared = 0.872
Expected
Outcome
3
4
The Linear Regression predicts that 1  2 drinks will add only a few putts.
0
1
2
3
4
5
6
D
r
i
n
k
s
Realistic
Tolerance
6Sigma Example  Control Phase
Monitoring the SPC Chart
99! Out of Control!
UCL = 96.91
LCL = 83.23
What happened here?
Let’s look at the data!
Does Larry’s Control Plan Work?
Score Drinks
89 1
91 1
88 1
90 2
99 4
91 2
88 0
89 1
90 2
93 2
91 1
“Stuff” happens  so we do
Risk Assessment / Abatement!!
Did the Abatement Work?
UCL
Control Chart
says Yes!
LCL
Capability Analysis says Yes!
He has reached Zlt = 5.7 Sigma!
(Zst at Measure was 5.64)
Success!