6 Sigma

Six sigma

Contents

Conclusion

What Is a Sigma? A metric that indicates how well a process is performing. Measures the capability of the process to perform defect-free work. For discrete data it is calculated from DPMO.

Sigma Level  2 3 4 5 6

Defect Rate

308,537 66,807 6,210 233 3.4

1,000,0 00

DEFECTS

100,0 00 10,0 00

Averag e Compa

1,00 0 10 0 1 0 1

Best-inClass

2

3

4

S

5

6

7

What is Six Sigma? •

It is a methodology for continuous improvement

•

It is a methodology for creating products/ processes that perform at high standards

•

It is a way of knowing where you are and where you could be!

•

It is a Quality Philosophy and a management technique

Note: Six Sigma is not: • A standard • A certification

Origin of Six Sigma Motorola

the company that invented Six Sigma • The term “Six Sigma” was coined by Bill Smith, an engineer with Motorola

1987 - Motorola officially launched it’s Six Sigma program

DMAIC

Six Sigma Improvement Methodology

What is DMAIC ? •

A logical and structured approach to problem solving and process improvement

•

An iterative process (continuous improvement)

•

A quality tool with focus on change management

E

Effectivene ss

=

Q

x

A

Quality Acceptance Improvement

The Approach Practic al

Statisti cal

Statistic al

Practic al

Methodology Identify and state the practical problem

Validate the practical problem by collecting data

Convert the practical problem to a statistical one, define statistical goal and identify potential statistical solution Confirm and test the statistical solution

Convert the statistical solution to a practical solution

Define Who wants the project/ Improvement and why ?

The scope of improvement

Key team members / resources for the project

Critical milestones and stakeholder review

Budget allocation

D

Measure Ensure measurement system reliability - Is tool used to measure the output variable flawed ? - Do all operators interpret the tool reading in the same way ?

Prepare data collection plan - How many data points do you need to collect ? -How many days do you need to collect data for ? -What is the sampling strategy ? -Who will collect data and how will data get stored ? -What could the potential drivers of variation be ? Collect data

M

Analyze Understand statistical problem

Baseline current process capability

Define statistical improvement goal

A

Identify drivers of variation (significant factors)

Improve Solution Design Developed And Documented

Solutions Tested On A Small Scale Or Pilot Program

I

Implementation Plan Developed And Executed

Contro l

ensures that the solution is working effectively

Procedures Documented

Sustenance Plan - Statistical Process Control - Mistake Proofing - Control Plan

C

Six Sigma Organization

The Quality Team Thought Leadership Expert on Six Sigma Mentor Green and Black Belts

Master Black Belt

Black Belt

Green Belt

Green Belt

Black Belt

Green Belt

Green Belt

Backbone of Six Sigma Org Mentor Green Belts Full time resource Deployed to complex or “high risk” projects

Part time or full time resource Deployed to less complex projects in areas of functional expertise

The Growth of Six Sigma Mumbai Dabbawala

CONCLUS ION Customer Happy

Six sigma is about reducing variations in a process

Thank you