This PPT will have description of Six Sigma Green Belt for one day training

1. Six Sigma Green Belt
Prepared by Raju, Syncolite india pvt ltd.

2. What is Six Sigma
Six sigma is the systematic method of problem
solving / process improvements statistically

3. Types of Six Sigma
• SS White & yellow Belt - Basic introduction
• SS Green Belt – Certification /to participate in the SS
project
• SS Black Belt –More information about SS
• SS Master Black Belt - Project head / Guide

4. Six Sigma is NOT
Just about Statistics
Used when Solution is
known
Only for Technical
People
A Quality Program

5. Fundamentals of Six
Sigma
There are 5 fundamental steps involved to achieve Six
sigma
• Define
• Measure
• Analysis
• Improve
• Control

6. Define
• Process Defining the problem thoroughly / Specifically.
• Identify Project and Project Owner
Determine Customer Requirements and CTQs
• Define Problem, Objective, Goals and Benefits
Define Stakeholder/Resource Analysis
• Map the Process
• Develop Project Plan

7. Measure
Process of finding the actual problem
• Determine Project Critical Xs and Ys
• Develop Data Collection and Sampling Plan
• Total Variation= System Variation + Process
Variation
• Validate the Measurements
• Determine Process Capability and Baseline
• Establish Performance Standards

8. Analyze
Process of finding the Root cause
o Analyze Activities
o Benchmark the Process or Product
Establish Causal Relationships Using Data
Analysis of the Process Map
Determine Root Cause(s) Using Data
o Analyze Quality Tools
o Statistical analysis of data
o Cause and effect diagram
o Histogram
o Pareto diagram
o Scatter graph
o Graphical Analysis (Histogram/Box Plot/Dot Plot/Run Chart/Scatter
Plot

9. Improve
o Improve Activities
o Develop Solution Alternatives
Assess Risks and Benefits of Solution Alternatives
Validate Solution using a Pilot
Implement Solution
Determine Solution Effectiveness using Data
o Improve Quality Tools
o Design of Experiments
o Brainstorming
o FMEA
o Risk assessment
• Correlation Analysis
• Multi variety Analysis
• Response Surface Methodology

10. Control
o Process of properly documented & Monitored
o Control Activities
o Determine Needed Controls (measurement, design, etc.)
Implement and Validate Controls
Realize Benefits of Implementing Solution
Close Project and Communicate Results
o Control Quality Tools
o Statistical Process Control
• Process Map and FMEA
• Control Plans
• Poka Yoke
• 5 S
• Control Charts

11.  Benchmark
 Baseline
 Kano Model
 Voice of the
Customer
 Quality Function
Deployment
 Process Flow Map
 Project
Management
 7 Basic Tools
 Defect Metrics
 Data Collection,
Forms, Plan,
Logistics
 Sampling
Techniques
 Cause & Effect
Diagrams
 Failure Models &
 Effect Analysis
 Decision & Risk
Analysis
 Statistical Inference
 Control Charts
 Capability
 Reliability Analysis
 Root Cause
Analysis
 5 Why’s
 Systems Thinking
 Design of
Experiments
 Modelling
 Tolerancing
 Robust Design
 Process Map
Statistical Controls
 Control Charts
 Time Series
Methods
Non Statistical
Controls
 Procedure
adherence
 Performance
Mgmt
 Preventive activities
 Poke yoke
Define
What is wrong?
Measure
Data & Process
capability
Analyze
When and where
are the defects
Improve
How to get
to six sigma
Control
Display
key measures
Tools for DMAIC

12. Evolution of Quality
Historically
Proactive Quality
“Create process that
will produce less or no
defects”
Contemporary
Reactive Quality
Quality Checks (QC) -
Taking the defectives
out of what is produced
Evolution of Quality

13. Six Sigma And Cost Of Quality
Six Sigma has a very significant impact on the cost of
quality. As the Sigma level moves up, the cost of quality
comes down and vice versa. Traditionally recorded quality
cost generally account for only 4 to 5 percent of sales which
mainly comprise of cost of scrap, re-work and warranty.
There are additional costs of quality which are hidden
and do not appear in the account books of the company,
as they are intangible and difficult to measure.

14. •Scrap
•Rework
•Warranty
costs
Hidden Costs
Visible costs
• Excessive use of material
• High inventory
• Inadequate resource utilization
• Cost of redesign and re-inspection
• Cost of resolving customer problems
• Lost customers
Visible And Hidden Costs
• Conversion efficiency of materials

15. Cost Of Quality At Various Levels Of Sigma
Sigma Defect rate(PPM) Cost of quality Competitive
level
3.4 <10%
233 10-15%
6210 15-20%
66807 20-30%
308537 30-40%
6,90000 >40%
World
Class
Industry
Average
Non
Competitive
6
5
4
3
2
1

16. What is The Cost Of Quality?
• Cost of Quality: the cost of ensuring that the job is done right + the
cost of not doing the job right.
Cost of Conformance + Cost of Non-Conformance
(Prevention & Appraisal) (Internal/External Defects)
1A.V. Feigenbaum, et al. (1950s) at GE, Tom Peters, “Quality is Free” (1980)

17. Cost Of Quality
Direct Costs
Prevention Costs
• Quality Planning
• Process Evaluation/Improvement
• Quality Improvement Meetings
• Quality Training
Appraisal Costs
• Source Inspection
• In/End-Process Inspection
• Calibration
• Specialist Cost
Internal Failure Costs
• Rework/Correction
• Re-Inspection
• Internal reject
• Loss of business
External Failure Costs
• Complaint Handling
• Rework/Correction
• Re-Inspection

18. Thank you