This presentation was presented @ 3rd Annual Lean Conference, 2015 @ AMA Ahmedabad, India.

1. Presentation
Title:
Apply Six Sigma with ease
Presented
on
2nd Feb 2015
@
3rd Annual Lean Conference,
AMA, Ahmedabad avci-lean.com

2. APPLY SIX SIGMA (6σ) WITH EASE

3. History of Six Sigma (6σ)
• In 1986 Bill smith, Seniors Engineer and scientist
introduces concept of Six Sigma
• Bill smith Known as “ Father of Six Sigma”
• In 1995, Jack Welch introduced Six Sigma at GE

4. μ
σ
What’s in a name?
• Sigma is the Greek letter representing the standard
deviation of a population of data
• Sigma is a measure
of variation
(the data spread)

5. What is Six Sigma ?
A
Methodology?
What is
Six Sigma?
A
philosophy?
A
metric?
A
Management
System?

6. What is Lean Six Sigma?
• Goal – Eliminate waste and increase process speed
• Method
– Genchi Genbutsu– Go and See the workplace (Gemba)
– Kaizen (Change for better) workshops
What is Lean ?

7. What is Lean Six Sigma?
• Goal – Reduce variation to improve performance on CTQs
(Variation means system does not produce same result each
time)
• Method – DMAIC, DMADV,DFSS approach
7
What is Six Sigma ?

8. Normal Distribution Curve
µ + -  - 1σ + 1σ
- 2σ + 2σ
68.26%
- 3σ + 3σ
+ 4σ
- 5σ
95.44%
99.73%
99.9937%
99.99943%
+ 5σ
- 6σ + 6σ
99.999998%
- 4σ
Lower
Spec
Upper
Spec

9. Sigma % Good % Bad DPMO
1 30.9% 69.1% 691,462
2 69.1% 30.9% 308,538
3 93.3% 6.7% 66,807
4 99.38% 0.62% 6,210
5 99.977% 0.023% 233
6 99.9997% 0.00034% 3.4
Defect Per Million Opportunity
(DPMO)

10. -6σ -5σ -4σ -3σ -2σ -1σ μ +1σ +2σ +3σ +4σ +5σ +6σ
? times σ
LSL
Mean
1σ
USL
Question - How many times of standard
deviation (σ) is specification limit to
mean?
Answer – Same as sigma level for the
process (Z value)
What is Six Sigma performance?
Your process is performing at sigma level of six if
the difference between mean and specification
limit is six times the standard deviation

11. Is it feasible to eliminate the inspection of Y, if X’s are controlled well?
•
•
•
•
•
•
•
Y
Dependent
Output
Effect
Symptom
Monitor
Response
•
•
•
•
•
•
•
X1 . . . XN
Independent
Input
Cause
Problem
Control
Factor
To get results, should we focus our behavior on the Y or X ?
f (X)Y=
Data Driven Approach

12. How Six Sigma Process Follows?
• Identify customer issues which generally follows timely
delay, high cost, defect etc…
• Internalized as performance measures such as
e.g. Cycle time, defect rate etc.
• Target performance levels are established and then
company seek to perform around this targetswith minimal
variation

13. THE DMAIC METHOD
IMPROVE
CONTROL
MEASURE
ANALYZE
5
2
3
4
DEFINE
1

14. Projects Identification Method
VOC ANALYSIS
(Problem
identification based on
customer’s voice)
VOB ANALYSIS
(Problem
identification based on
Business problems)
COPQ (Problem
identification based on
cost of poor quality
i.e. Process Defects )
Identificationof
CTQs
List of
problems/projects of
organization on the
basis of Criticality, Out
come , Time line
Phase 1: Define

15. Phase 2: Measure
• Goal
– Focus the
improvementeffort by
gathering information
on the current
situation
• Output
– Data that pinpoints
problem location or
occurrence
– Baseline data on
currentprocess sigma
– A more focused
problem statement
IMPROVE
CONTROL
ANALYZE
5
3
4
DEFINE
1
MEASURE
2

16. DATA COLLECTION
• The system to collect information is already established.
• Find the data which supportsthe defined problem
• Find out the data stream wise/ productwise etc..
Datatype:
• Attribute data or Discreet : Value of countablequality characteristics
Example - Number of Defects, Number of Defectives.
• Continuousdata or Variable data : Value of measurable quality
characteristics
Examples - Strength (kg/cm2), weight (kg) , length (cm), temperature (° C),
time (sec)

17. Phase 3: Analyze
IMPROVE
CONTROL
MEASURE
ANALYZE
5
2
3
4
DEFINE
1
• Goal
– Identify deep root
causes and confirm
them with data
• Output
– A theory that has
been tested and
confirmed

18. Phase 4: Improve
• Goal
– Develop, pilot, and
implement solutions
that address root
causes
• Output
– Identification of
planned, tested
actions that should
eliminate or reduce
the impact of the
identified root causes
CONTROL
MEASURE
ANALYZE
5
2
3
DEFINE
1
FMEA
IMPROVE
4

19. Solutions
• Improvement team created with members of Quality,
Production, Engineering and R&D areas to propose and
evaluate ideas
• Brainstorming tool was used to gather ideas on how to solve
the problems identified
• Ideas were evaluated per following criteria: feasible, high
impact, easy, low cost, and quick
• Following tables summarizes solutions agreed by consensus of
the improvement team

20. Phase 5: Control
• Goal
– Use data to evaluate both the
solutions and the plans
– Validate that all changes adhere to all
operating company change control,
and compliance requirements
– Maintain the gains by standardizing
processes
– Outline next steps for on-going
improvement
• Output
– Before-and-After analysis
– Monitoring system
– Completed documentation of results,
learning, and recommendations
IMPROVE
CONTROL
MEASURE
ANALYZE
5
2
3
4
DEFINE
1

21. Standardization
– All new tooling, processes, clarifications, and
visual aids documented
– Creation of MOPXXX with all the quality criteria
for Variable Lasso Deflection and Contraction
performance.

22. Monitoring
Work Orders
Built
Yield
Goal
Scrap
Produced
Yield
Actual

23. I-MR Charts of Burst Tester
Burst Values
IndividualValue
302928272625242322212019181716151413121110987654321
115
110
105
100
_
X=105.88
UCL=113.76
LCL=97.99
Observation
MovingRange
302928272625242322212019181716151413121110987654321
10
5
0
__
MR=2.97
UCL=9.69
LCL=0
Universal Tray Packaging (CA Sealer)
In-H20
Burst Values
IndividualValue
302928272625242322212019181716151413121110987654321
110
105
100
95
_
X=100.72
UCL=109.68
LCL=91.76
Observation
MovingRange
302928272625242322212019181716151413121110987654321
12
8
4
0
__
MR=3.37
UCL=11.01
LCL=0
Universal Tray Packaging (Juarez Sealer)
In-H20

24. Thank You