6 Sigma lean

1. A short introduction
Hans van Veen
May 2013.

2. Sigma
&
Defects
relation

3. 4.6 sigma means
● 4000 newborns accidently being
dropped after birth per year
● 2 highly problematic landings
each day on US airports
● 400 lost letters per hour at
US-Post

4. 6 sigma means
● 10 newborns accidently being
dropped after birth per year
● 2 problematic landings each
year on US airports.
● 1 lost letter per hour at US-Post
● Watch off by 2 seconds in 31
years

5. Some other data
● Restaurant bills, doctors prescription
writing, and payroll processing – 2.9 σ
● Average company – 3.0 σ
● Airline baggage handling – 3.2 σ
● Best in class companies – 5.7 σ
● U.S. Navy aircraft accidents – 5.7 σ
● Airline industry fatality rate – 6.2 σ

6. Six Sigma can be used as:
● a metric
● a methodology
● a management
system

7. As a Metric
A tool to measure process variation.

8. As a Methodology
● Consistent use of DMAIC-Models.
● Team based problem solving.
● Mesurement based Process Analysis,
Improvement and Control.

9. As a Management System
● Six Sigma drives strategy execution.
● Leasdership, sponsorship and review.
● Metrics driven governance process.
● Engagement across the organization.

10. One of the metrics: 5S

11. Brainstorming

12. Statistical Process Control

13. Design of Experiments
Spot welding schedule set up with a 3³ design.
● 3 levels for electrode pressure
● 3 levels for current
● 3 levels for time
Optimal combination is
somewhere in the cube
and can be found easily
with dedicated software
(Minitab, SAS, SPSS,
Cornerstone, R-DoE.
Result
Trial & Error ==> DoE:
3 days ==> 4 hours.

14. Problem Solving
Sieve deck lifetime was 5 weeks.
● Ishikawa diagram (Fishbone)
● FMEA
●
Choise of best possible solution (Adhesive)
● Experimental sieve deck manufactured
● New deck followed and measured regularly
New lifetime ==> 8 months.
Yearly savings ==> 150 k€
Much more important ==> Process stabilisation

15. 6 Sigma and Related Techniques

16. Warning

17. Thank you.
Questions ?