Six Sigma

Six Sigma : Concept, Role in Quality, Implementation Techniques and Benefits

1. SIX SIGMA 6ϭ SUBJECT : PRODUCTION AND QUALITY MANAGEMENT

2. CONTENTS SIX SIGMA : INTORDUCTION ROLE OF SIX SIGMA IMPLEMENTATION OF SIX SIGMA DMAIC Methodology DMADV Methodology SIPOC Methodology BENEFITS OF SIX SIGMA

3. SIX SIGMA: INTRODUCTION Business Improvement Approach Focus of Six Sigma 1 Reducing variability in key product quality characteristics to the level at which failure or defects are extremely unlikely Tasks through 6 σ achieved in corporate business 1 : Improving quality critical for customers Reducing costs Objectives of Six Sigma program: Enhanced product quality, yield and cost – all of which, in turn, improve customer satisfaction 2

4. SIX SIGMA Six Sigma is a set of process improvement techniques and tools in statistical quality control , mainly applied to make customer happier and increase profits

5. N σ DPMO* YIELD 1 σ 691462 30.8538 2 σ 308538 69.1462 3 σ 66807 93.3193 4 σ 6210 99.3790 5 σ 233 99.9767 6 σ 3.4 99.9997 * Defects per Million Oppurtunity The term “Sigma (б)” refers to measure of variation.

6. SIX SIGMA: HISTORY

7. Mumbai Dabbawala That's too with limited resources

8. Criterias for Applying Six Sigma Project Impact on the bottom line : “$” Profit Justification to the Quality Gained Applications – Does it need the SIX SIGMA ?

9. GE Six Sigma Economics

10. ROLE OF SIX SIGMA OBJECTIVES OF 6 σ : Improve customer satisfaction Improve quality of product and service Reduce process cycle time Overall cost saving Development of Staff Skill Eliminating Waste or Defects WHERE 6 σ IS USED Manufacturing and service industries Sales and marketing Accounting and financing

11. IMPLEMENTATION OF SIX SIGMA DMAIC DMADV Six Sigma Methodology inspired by Deming's Plan-Do-Check-Act Cycle SIPOC

12. STEPS DEFINITION TOOLS USED Define Defin e the problem or project goal that needs to be addressed FMEA Process Flow Chart Value Added Flow Chart Measure Measure the current performance in various aspects. It is a data collection step MSA SPC Histogram and Pareto Chart Analysis Analyse the process to determine root causes of variation, poor performance(defects) DoE Why-5 Cause and Effect Diagram Improve Improve process performance by addressing and eliminating the root causes 5S TPM Kaizen Control Control improved process and future process performance Control Plan Standardized Work Check Sheet SPC DMAIC

13. STEPS DEFINITION Define D efine design goals that are consistent with customer demands and the enterprise strategy Measure M easure and identify CTQs (characteristics that are C ritical T o Q uality), measure product capabilities, production process capability, and measure risks. Analysis A nalyze to develop and design alternatives Define D esign an improved alternative, best suited per analysis in the previous step Verify V erify the design, set up pilot runs, implement the production process and hand it over to the process owner(s) DMADV The DMADV methodology, instead of the DMAIC methodology, should be used when: A product or process is not in existence at your company and one needs to be developed The existing product or process exists and has been optimized but still does not meet the level of customer specification or Six Sigma level

14. SIPOC SIPOC is a high-level view of a process Lean – Six Sigma Approach

15. SIX SIGMA: BENEFITS Enhanced ability to provide value to customer Enhanced understanding of business processes Reduction of Waste Improved profit performance Make customer happier

16. Summary Dr. W. Edwards Deming proposed to eliminate slogans and programs to improve quality, rather he advised to work to improve the system and provide information on that. 1 Six Sigma is the improvement process in which various techniques and tools are used to decrease variability in production and increase profit with statistical quality control, DMAIC and DMADV are six sigma implementation methodologies inspired by Sir Deming’s Plan-Do-Check-Act cycle

17. Questions Explain Six Sigma and its objectives ? Enlist Six Sigma methodologies and explain DMAIC ?

18. References Douglas C. Montgomery, Introduction To Statistical Quality Control, John Wiley & Sons, Fourth Edition, Pg. 23 Mikel J. Harry, The Nature of Six Sigma Qualit y, Motorola Inc., 1986 .