Six Sigma Principles.pdf

Six Sigma Principles

1. Andreas MahendroKuncoro, S.T., M.Sc., M.Sc., Ph.D.

2. Agenda
•Review main objective of 6 Sigma
•DMAIC vs DMADV (DFSS)
•Key factor success of 6 Sigma
implementation
•Principles of 6 Sigma

3. PROCESS TIME
VARIABILITY
DEFFECTS / ERRORS
Sigma Sigma
aims to
improve
quality by:
Customer
Satisfaction and
Loyalty
Employees Morale
Increase of Reduction of
Providing clear
roadmap

4. DMAIC vs DMADV
DMAIC
•Emphasis on correctingexisting
processes and reducing existing
variation
•“Correction” / Reactive
•Focus on process
•Short term
•Continuous improvement
(incremental change needed)
DMADV
•Emphasis on creatingprocess
with an optimize design “doing
it the first time?
•“Prevention” / Proactive
•Focus on customer
•Long Term
•Reengineering(evolutionary
change)

5. Six Sigma Problem Solving Workflow -DMAIC
Define
Why must this project
be done NOW?
What is the
problem/opportunity
and end goal?
What is the scope pf
this project?
Who is the
stakeholder?
What will be future
state?
Measure
What is are the key
metrics for this
business process?
Are metrics valis and
reliable?
Do we have adequate
data?
How will I measure
progress?
Analyze
Why defects, errors,
excessive variation
occur?
Develop Cause-effect
analysis of the
problem
Is the current state as
good as the process
can do?
What could cause this
change effort to fail?
What major obstacles
do I face in completing
this project?
Improve
Creating change or
optimize the current
process
Do the changes
produce desired goal?
Any unanticipated
consequences?
Control
Ensure any deviations
from the target are
corrected before they
results in defects
Ensure that the
business goals of the
project are
accomplished
How will I control risk,
quality, cost, schedule,
scope and changes to
plan?

6. Six Sigma Problem Solving Workflow -DMADV
Define
Why must this project
be done NOW?
What is the problem
and end goal?
What is the scope pf
this project?
Who are the
customers? Define
their needs
What will be future
state?
Measure
What is are the key
metrics for this
business process?
How does customers
response to the
product?
Do we have adequate
data?
How will I measure
progress?
Analyze
Are the products
aligned with the
customer needs
Design
Design and optimize
the process details to
ensure customer
needs are met
Do the changes
produce desired goal?
Any unanticipated
consequences?
Verify
How well the design
meet the customer
needs?
Ensure that the
business goals of the
project are
accomplished
How will I control risk,
quality, cost, schedule,
scope and changes to
plan?

7. Key Success
Factors
implementing 6
Sigma
Leadership
Infrastructure
Communication
and Awareness
Stakeholder
Feedback
Systems
Process
Feedback
System
Project
Selection

8. Six Sigma Principles
1.Concept of variation
2.Process focus
3.Voice of the Customer
4.Value of Six Sigma
5.Empowerment
6.Team building/team work/participative
7.Value stream
8.Systems thinking
9.Statistical thinking
10.Conflict resolution
11.Process performance
12. Cost of quality
13. Measurement
14. Lean principles: value, value chain, flow and
perfection
15. Training and Education
16. Pull
17. Standardization
18. Continuous improvement and Kaizen
19. Learning and knowledge transfer

9. 6 Sigma Principle -
Concept of Variation
•Variation
•Differences between an
ideal and actual situation
•Type
•Common Cause
•Special Cause –
unusual/abnormal
circumstance

10. 6 Sigma
Principle -
System
Thinking
•System:
"A set of elementsthat are
interrelatedand influencedeach
other in carrying out activities
together to achieve a goal"
"A system is a collection of
elements consisting of human
resources and the other resources (
materials, machines, procedures,
documents, data or other
elements) that are organizedto
achieve a goal. Without human,
system cannot run"

11. Karakteristik
Sistem
Komponen/Elemen
(component)
Batas sistem
(boundary)
Lingkungan luar
sistem
(environment)
Penghubung
(interface)
Masukan (input) Pengolah (process)
Keluaran (output) Sasaran (objective)
atau tujuan (goal)

13. Context Input Proses Output Outcome
Resources:
H.R.
Material
Capital
Tool
Energy
Etc.
Products:
Goods
Service
Physic: Manufacture
Location: transportation
Exchange: retail
Phycology: Entertainment
Etc.
System
Added Value
Environment:
Demand
Government Policy
Global Situation
Technology
Development
Etc.
Profit
Community
Welfare
dan lain-lain
•Performance Metric:
Effectiveness, Efficiency, Productivity, Quality, Innovativeness,
Sustainability, Growth

14. •Manufacturing Systems: machinery, operators, goods, etc.
•Education System: human resources, curriculum, infrastructure
facilities, learners, learning, etc.
•Hospital System: doctors, nurses, sick people, admins, medical
equipment, consultations, surgical operations, medications, etc.
•Transportation System: road elements, vehicles, humans,
regulations, etc.
•Human body system: sub digestive system, respiratory sub-
system, etc.
Examples of Systems

15. Nature of the system
•Complete
•All elements required to achieve a goal
•Proper
•All components in the system have proper
functions/roles.
•System Thinking
•Think and act holistically and integratively,
•"interaction and synergy" between
elements in the system in order to achieve
goal

16. (Hadjisaroso, Purnomosidi, 2003. Pendekatan sistem dalam manajemen dan bisnis)

18. ManufakturdanProduksi
•PerakitanBarang
•Pemeriksaankualitas
PenjualandanPemasaran
•Identifikasipelanggan
•Memperkenalkanproduk
•Menjualproduk
Keuangandanakuntansi
•Membuatlaporankeuangan
•MengelolaKeuangan
SumberDayaManusia
•MerekrutKaryawan
•Mengevaluasikinerja manusia

19. Order Fulfillment Process