ISI, SQC UNIT, BANGALORE

SS-DEFINE PHASE

THE MANY FACETS OF SIX SIGMA S I X S I G M A

Metrics Metrics Benchmark Benchmark Vision Vision Philosophy Philosophy Method Method Tool Tool Symbol Symbol Goal Goal Value Value
1

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WHAT IS THIS SIX SIGMA ?

A Philosophy make fewer mistakes in all that we do.

A Statistical Measurement helps gage adequacy of product, process and services A Metric A Business Strategy A measuring system good quality reduces cost

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SS-DEFINE PHASE

SIGMA RATING AND PPM ARE CORRELATED Sigma Rating Sigma Rating
2 2 3 3 4 4 5 5 6 6 Process Process Capability Capability SIGMA RATING

PPM PPM
308,537 308,537 66,807 66,807 6,210 6,210 233 233 3.4 3.4 Defects per Defects per Million Opportunities Million Opportunities

A PERFORMANCE MEASURE
3

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SS-DEFINE PHASE

THE GOALS OF SIX SIGMA

TO REDUCE VARIATION TO REDUCE DEFECTS TO IMPROVE YIELD TO ENHANCE CUSTOMER SATISFACTION TO IMPROVE THE BOTTOMLINE

ISI, SQC UNIT, BANGALORE

SS-DEFINE PHASE

THE FOCUS OF SIX SIGMA

Y = f(X)
Y Dependent variable Output of the process Effect Symptom It is monitored X1, X2, .., Xn Independent variable Input to the process Cause Problem It is controlled

To get results should we focus on Y or X?

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SS-DEFINE PHASE

APPROACH TO DEFINE

Develop Business Develop Business Case and Case and Team Charter Team Charter

Map the Map the current current process process

Listen to the Listen to the Voice of the Voice of the Customer Customer

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SS-DEFINE PHASE

PREVIEW OF DEFINE STEP

The subsequent discussions will take you through
Selecting a project and drafting a charter A basic SIPOC analysis Gathering/confirming the Voice of the Customer (Effectiveness goals e.g. On time delivery) and/or the Voice of the Business (Efficiency goals e.g. reduction of inventory).

ISI, SQC UNIT, BANGALORE

SS-DEFINE PHASE

GOALS
Understand the organizational context for process improvement projects. Understand how to select a DMAIC project and be able to apply the criteria to your own project. Know the basic elements of the project charter and be able to develop a charter for your own project. Understand the basics of estimating the business impact of a project and be able to relate them to your own project. Be able to identify key players and stakeholders and incorporate them into the communication plan for your own project.
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SS-DEFINE PHASE

ORGANIZATIONAL CONTEXT FOR PROJECTS

Champions/ Sponsors

Master Black Belt

Coordinators

Black Belt Green Belt

Team Members

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SS-DEFINE PHASE

DMAIC PROJECT SELECTION CRITERIA

Projects will likely have greater success if
The problem is related to a key business issue. The problem is linked to a clearly defined process (you can identify the starting and ending points). You can identify the internal or external customers who use or receive the output from this process. You know or can find out how the customers use the output. You know or can find out what is important to the customer about the output.
10

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SS-DEFINE PHASE

DMAIC PROJECT SELECTION CRITERIA

You can clearly identify what a defect is and count its occurrence You can demonstrate how improvements could enhance financial performance There is appropriate organizational support The champion cares about this work and wants to make it happen The champion has the authority to commit time and resources A process owner has been identified

11

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SS-DEFINE PHASE

COMMON PROBLEMS AND RECOMMENDATIONS

Many projects encounter one or more of the following problems:
Not relevant to customers or to business needs Project scope too large; wont have authority to commit time/resources or to make changes in the process; cant easily identify starting and ending points Relevant data hard to collect or too much data Cant define what a defect is Process doesnt cycle often enough Problem written as solution Recent changes in the process
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SS-DEFINE PHASE

ELEMENTS OF A PROJECT CHARTER

Project Description Scope Goals and Measures (indicators) Expected Business Results Team Members Support Required Expected Customer Benefits Schedule
13

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SS-DEFINE PHASE

QUALITY AND PROCESSES

Quality is judged by customers based on the output of a process. Focusing on the work of the individual worker will not lead to greatly improved quality. To improve quality, the process must be improved. Simply focusing on or defining a process is NOT improvementwe have to make changes and use data to show the change really is an improvement.
14

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SS-DEFINE PHASE

WORK AS A PROCESS
S U P P L I E R S C U S T O M E R S

Inputs

Process

Outputs

Applies to all kinds of work, whether repetitive in nature or one-of-a-kind. Having a high-level view of a process helps to:
define project boundaries (starting and ending points); describe where to collect data.
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SS-DEFINE PHASE

SIPOC EXAMPLE
Suppliers
Manufacturer Office Supply Company

Inputs
Copier

Process

Outputs
Copies

Customers
You

Paper

File

Toner

Making a photocopy

Others

Yourself

Original

Power Company

Electricity

Process Steps
Remove Remove originals originals and copies and copies

Put original Put original on glass on glass

Close Lid Close Lid

Adjust Adjust Settings Settings

Press Press START START

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SS-DEFINE PHASE

TRANSLATING VOC/VOB INTO CTQs

VOC/VOB CTQ Tree
CTQ CTQ

I want

CTQ

need

CTQ CTQ CTQ CTQ CTQ

(CTQ = Critical to Quality)

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SS-DEFINE PHASE

EXAMPLE: CTQ TREE

Need Drivers CTQs
Low qualification of operator Operation Easy to setup (training / documentation) Digital Control MTBF Ease of Operation and Maintenance Maintenance Mistake Proofing Skills and Knowledge Mistake Proofing Documentation Minimum special tools / equipment required

Modification

General Hard to measure

Specific Easy to measure 18

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SS-DEFINE PHASE

APPROACH TO MEASURE

Collect baseline data on defects and possible causes

Develop a Sampling Strategy

Validate your measurement system using Gage R&R

Analyze patterns in data

Determine process capability

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SS-DEFINE PHASE

DATA GATHERING
What is Data ? Data is a numerical expression of an activity. Conclusions based on facts and data are necessary for any improvement. -K. Ishikawa If you are not able to express a phenomenon in numbers, you do not know about it adequately. -Lord Kelvin
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TYPES OF DATA
CONTINUOUS Measurable e.g. :Length, Temperature DISCRETE Subjective Assessment e.g. :Score in a beauty contest Countable e.g. :Number of defects

Data if properly collected Least influenced by individual biases Could be subject to critical analysis Generally beyond language barriers and therefore universal in expression.
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SS-DEFINE PHASE

WHICH OF THE BELOW ARE CONTINUOUS AND DISCRETE DATA?

Width of sheet No. of liners thinned Tubes rejected by Go- Nogo Gauge Diameter of Piston Height of a Man Sheet thickness Out of 100 sheets the numbers that meet the thickness 4 0.9 Time taken to process a purchase order No. of bugs in a program
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SS-MEASURE PHASE

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SS-DEFINE PHASE

WHAT IS THE MEASURE WHAT IS THE MEASURE OF CENTRAL TENDENCY OF A SET OF OF CENTRAL TENDENCY OF A SET OF NUMBERS? NUMBERS?
There are three ways in which Central Tendency of Numbers can be measured. These are the 3 Ms

MEAN MEDIAN MODE

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SS-DEFINE PHASE

MEASURES OF DISPERSION MEASURES OF DISPERSION

The extent of the spread of the values from the mean value is called Dispersion. The measures of Dispersions are Range (R) Standard Deviation (s) Variance (s2) Co-efficient of Variation (CV)

Standard deviation is the most commonly used measure of dispersion.

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SS-DEFINE PHASE

WHAT IS VARIATION ?
No two things in nature are alike. This is also true for manufactured products. This dissimilarity between two products for the same characteristic is called variation. The variation may be or can be made to be so small so as to make the product SEEM similar. When we say that 2 things are similar we actually mean that it is not possible to measure the variation present within the accuracy of the existing measuring equipment. Variation between 2 products are compared for SIMILAR features or characteristics.
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SS-DEFINE PHASE

TYPES OF VARIATION

Variations among pieces at the same time Variations across time

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SS-DEFINE PHASE

GRAPHICAL DISPLAY OF VARIABILITIES

CASE I Assignable (Black noise) Assignable Variability Variability Inherent Variability
Aimed Value
T O T A L V A R I A B I L I T Y
28

Assignable Variability CASE II

Assignable Variability

CASE III

ISI, SQC UNIT, BANGALORE

SS-DEFINE PHASE

GENERIC CAUSES OF VARIATION

Machines Materials Methods Measurements Mother Nature People

P P R R O O C C E E S S S S
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SS-DEFINE PHASE

68.26

95.46

-3

-2

-1

+1

+2

+3

99.73

THE NORMAL DISTRIBUTION

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SS-DEFINE PHASE

IMPORTANT SPC RATIOS USED

LSL x USL

-3

+3

Cp = =

Maximum allowable range of characteri stic Normal variation of process

Tolerance USL - LSL = 6s 6s This compares the requirement of the process output vis-a-vis the inherent variability of the process. Higher value than 1 implies that the process has got the capability to give the product within the set limits.
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SS-DEFINE PHASE

USL - X Cpu = 3s This gives us the positioning of the mean vis-a-vis the USL and the relationship between the two. X LSL Cpl = 3s This gives us the positioning of the mean vis-a-vis the LSL and the relationship between the two.

Cpk - Process Performance Index. This is important

Cpk = Minimum of (Cpu and Cpl) ; for bilateral tolerances = Cpu ;for unilateral tolerance on upper side i.e.. X = Cpl ;for unilateral tolerance on lower side i.e.. X
+Y -O

+O -Y

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SS-DEFINE PHASE

THE CONCEPT OF OPPORTUNITY

Every possibility of making an error is called an opportunity The total opportunities available for an error to take place are Nos.Chkd. x Opp If there are more than 1 opp. The sigma can be calculated by finding DPMO. Knowing DPMO we refer to the Normal Dist. Table to get the Sigma value One could inflate the opp. and hence get an enhanced Sigma But the opp.are limited to what exactly is checked for. E.g. a sheet is checked for thickness, length & width and can be rejected for either.Hence the opp. is 3 DPMO = Defects x 1066 DPMO = Defects x 10 Units chkd. x Opp. Units chkd. x Opp.
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SS-DEFINE PHASE

A FEW TERMINOLOGIES
Defect : Any non-conformity in a product or service
e.g. Late delivery or no. of tubes rejected

Units : The nos. checked or inspected 100 deliveries were monitored for being late, no. of units
are 100 1000 tubes were checked for oversize dia., no. of units are 1000

Opportunity : Anything that you measure or check for.

Finished refrigerator is checked for 25 defects at final inspection, the no. of opportunities is 25

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SS-DEFINE PHASE

THE SIGMA RATING

This Z value is known as the SIGMA RATING Knowing the sigma rating we can establish the rejections that can be expected from the process The average, the standard deviation & the specification limits are required to get the sigma rating There are 2 kinds of sigma ratings.The short term Sigma & the long term Sigma (to be seen in detail later) One should not confuse between the sigma rating & the standard deviation
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SS-DEFINE PHASE

Sigma and DPMO conversion table

Sigma 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.20 0.21 0.22 0.23 0.24 0.25 DPMO Sigma DPMO Sigma DPMO Sigma DPMO Sigma DPMO Sigma DPMO Sigma DPMO Sigma DPMO 931888 0.26 892512 0.51 838913 0.76 770350 1.01 687933 1.26 594835 1.51 496011 1.76 397432 930563 0.27 890651 0.52 836457 0.77 767305 1.02 684386 1.27 590954 1.52 492022 1.77 393580 929219 0.28 888767 0.53 833977 0.78 764238 1.03 680822 1.28 587064 1.53 488033 1.78 389739 927855 0.29 886860 0.54 831472 0.79 761148 1.04 677242 1.29 583166 1.54 484047 1.79 385908 926471 0.30 884930 0.55 828944 0.80 758036 1.05 673645 1.30 579260 1.55 480061 1.80 382089 925066 0.31 882977 0.56 826391 0.81 754903 1.06 670031 1.31 575345 1.56 476078 1.81 378281 923641 0.32 881000 0.57 823814 0.82 751748 1.07 666402 1.32 571424 1.57 472097 1.82 374484 922196 0.33 878999 0.58 821214 0.83 748571 1.08 662757 1.33 567495 1.58 468119 1.83 370700 920730 0.34 876976 0.59 818589 0.84 745373 1.09 659097 1.34 563559 1.59 464144 1.84 366928 919243 0.35 874928 0.60 815940 0.85 742154 1.10 655422 1.35 559618 1.60 460172 1.85 363169 917736 0.36 872857 0.61 813267 0.86 738914 1.11 651732 1.36 555670 1.61 456205 1.86 359424 916207 0.37 870762 0.62 810570 0.87 735653 1.12 648027 1.37 551717 1.62 452242 1.87 355691 914656 0.38 868643 0.63 807850 0.88 732371 1.13 644309 1.38 547758 1.63 448283 1.88 351973 913085 0.39 866500 0.64 805106 0.89 729069 1.14 640576 1.39 543795 1.64 444330 1.89 348268 911492 0.40 864334 0.65 802338 0.90 725747 1.15 636831 1.40 539828 1.65 440382 1.90 344578 909877 0.41 862143 0.66 799546 0.91 722405 1.16 633072 1.41 535856 1.66 436441 1.91 340903 908241 0.42 859929 0.67 796731 0.92 719043 1.17 629300 1.42 531881 1.67 432505 1.92 337243 906582 0.43 857690 0.68 793892 0.93 715661 1.18 625516 1.43 527903 1.68 428576 1.93 333598 904902 0.44 855428 0.69 791030 0.94 712260 1.19 621719 1.44 523922 1.69 424655 1.94 329969 903199 0.45 853141 0.70 788145 0.95 708840 1.20 617911 1.45 519939 1.70 420740 1.95 326355 901475 0.46 850830 0.71 785236 0.96 705402 1.21 614092 1.46 515953 1.71 416834 1.96 322758 899727 0.47 848495 0.72 782305 0.97 701944 1.22 610261 1.47 511967 1.72 412936 1.97 319178 897958 0.48 846136 0.73 779350 0.98 698468 1.23 606420 1.48 507978 1.73 409046 1.98 315614 896165 0.49 843752 0.74 776373 0.99 694974 1.24 602568 1.49 503989 1.74 405165 1.99 312067 894350 0.50 841345 0.75 773373 1.00 691462 1.25 598706 1.50 500000 1.75 401294 2.00 308538

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SS-DEFINE PHASE
DPMO Sigma 65522 3.26 64256 3.27 63008 3.28 61780 3.29 60571 3.30 59380 3.31 58208 3.32 57053 3.33 55917 3.34 54799 3.35 53699 3.36 52616 3.37 51551 3.38 50503 3.39 49471 3.40 48457 3.41 47460 3.42 46479 3.43 45514 3.44 44565 3.45 43633 3.46 42716 3.47 41815 3.48 40929 3.49 40059 3.50 DPMO Sigma 39204 3.51 38364 3.52 37538 3.53 36727 3.54 35930 3.55 35148 3.56 34379 3.57 33625 3.58 32884 3.59 32157 3.60 31443 3.61 30742 3.62 30054 3.63 29379 3.64 28716 3.65 28067 3.66 27429 3.67 26803 3.68 26190 3.69 25588 3.70 24998 3.71 24419 3.72 23852 3.73 23295 3.74 22750 3.75 DPMO Sigma 22216 3.76 21692 3.77 21178 3.78 20675 3.79 20182 3.80 19699 3.81 19226 3.82 18763 3.83 18309 3.84 17864 3.85 17429 3.86 17003 3.87 16586 3.88 16177 3.89 15778 3.90 15386 3.91 15003 3.92 14629 3.93 14262 3.94 13903 3.95 13553 3.96 13209 3.97 12874 3.98 12545 3.99 12224 4.00 DPMO 11911 11604 11304 11011 10724 10444 10170 9903 9642 9387 9137 8894 8656 8424 8198 7976 7760 7549 7344 7143 6947 6756 6569 6387 6210

Sigma and DPMO conversion table

Sigma 2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25 DPMO Sigma DPMO Sigma DPMO Sigma DPMO Sigma 305026 2.26 223627 2.51 156248 2.76 103835 3.01 301532 2.27 220650 2.52 153864 2.77 102042 3.02 298056 2.28 217695 2.53 151505 2.78 100273 3.03 294598 2.29 214764 2.54 149170 2.79 98525 3.04 291160 2.30 211855 2.55 146859 2.80 96801 3.05 287740 2.31 208970 2.56 144572 2.81 95098 3.06 284339 2.32 206108 2.57 142310 2.82 93418 3.07 280957 2.33 203269 2.58 140071 2.83 91759 3.08 277595 2.34 200454 2.59 137857 2.84 90123 3.09 274253 2.35 197662 2.60 135666 2.85 88508 3.10 270931 2.36 194894 2.61 133500 2.86 86915 3.11 267629 2.37 192150 2.62 131357 2.87 85344 3.12 264347 2.38 189430 2.63 129238 2.88 83793 3.13 261086 2.39 186733 2.64 127143 2.89 82264 3.14 257846 2.40 184060 2.65 125072 2.90 80757 3.15 254627 2.41 181411 2.66 123024 2.91 79270 3.16 251429 2.42 178786 2.67 121001 2.92 77804 3.17 248252 2.43 176186 2.68 119000 2.93 76359 3.18 245097 2.44 173609 2.69 117023 2.94 74934 3.19 241964 2.45 171056 2.70 115070 2.95 73529 3.20 238852 2.46 168528 2.71 113140 2.96 72145 3.21 235762 2.47 166023 2.72 111233 2.97 70781 3.22 232695 2.48 163543 2.73 109349 2.98 69437 3.23 229650 2.49 161087 2.74 107488 2.99 68112 3.24 226627 2.50 158655 2.75 105650 3.00 66807 3.25

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SS-DEFINE PHASE

Sigma and DPMO conversion table

Sigma DPMO Sigma DPMO Sigma DPMO Sigma DPMO Sigma DPMO Sigma DPMO Sigma DPMO Sigma DPMO 4.01 6037 4.26 2890 4.51 1306 4.76 557 5.01 224 5.26 85 5.51 30.4 5.76 10.2 4.02 5868 4.27 2803 4.52 1264 4.77 538 5.02 216 5.27 82 5.52 29.1 5.77 9.8 4.03 5703 4.28 2718 4.53 1223 4.78 519 5.03 208 5.28 78 5.53 27.9 5.78 9.4 4.04 5543 4.29 2635 4.54 1183 4.79 501 5.04 200 5.29 75 5.54 26.7 5.79 8.9 4.05 5386 4.30 2555 4.55 1144 4.80 483 5.05 193 5.30 72 5.55 25.6 5.80 8.5 4.06 5234 4.31 2477 4.56 1107 4.81 467 5.06 185 5.31 70 5.56 24.5 5.81 8.2 4.07 5085 4.32 2401 4.57 1070 4.82 450 5.07 179 5.32 67 5.57 23.5 5.82 7.8 4.08 4940 4.33 2327 4.58 1035 4.83 434 5.08 172 5.33 64 5.58 22.5 5.83 7.5 4.09 4799 4.34 2256 4.59 1001 4.84 419 5.09 165 5.34 62 5.59 21.6 5.84 7.1 4.10 4661 4.35 2186 4.60 968 4.85 404 5.10 159 5.35 59 5.60 20.7 5.85 6.8 4.11 4527 4.36 2118 4.61 936 4.86 390 5.11 153 5.36 57 5.61 19.8 5.86 6.5 4.12 4397 4.37 2052 4.62 904 4.87 376 5.12 147 5.37 54 5.62 19.0 5.87 6.2 4.13 4269 4.38 1988 4.63 874 4.88 362 5.13 142 5.38 52 5.63 18.1 5.88 5.9 4.14 4145 4.39 1926 4.64 845 4.89 350 5.14 136 5.39 50 5.64 17.4 5.89 5.7 4.15 4025 4.40 1866 4.65 816 4.90 337 5.15 131 5.40 48 5.65 16.6 5.90 5.4 4.16 3907 4.41 1807 4.66 789 4.91 325 5.16 126 5.41 46 5.66 15.9 5.91 5.2 4.17 3793 4.42 1750 4.67 762 4.92 313 5.17 121 5.42 44 5.67 15.2 5.92 4.9 4.18 3681 4.43 1695 4.68 736 4.93 302 5.18 117 5.43 42 5.68 14.6 5.93 4.7 4.19 3573 4.44 1641 4.69 711 4.94 291 5.19 112 5.44 41 5.69 14.0 5.94 4.5 4.20 3467 4.45 1589 4.70 687 4.95 280 5.20 108 5.45 39 5.70 13.4 5.95 4.3 4.21 3364 4.46 1538 4.71 664 4.96 270 5.21 104 5.46 37 5.71 12.8 5.96 4.1 4.22 3264 4.47 1489 4.72 641 4.97 260 5.22 100 5.47 36 5.72 12.2 5.97 3.9 4.23 3167 4.48 1441 4.73 619 4.98 251 5.23 96 5.48 34 5.73 11.7 5.98 3.7 4.24 3072 4.49 1395 4.74 598 4.99 242 5.24 92 5.49 33 5.74 11.2 5.99 3.6 4.25 2980 4.50 1350 4.75 577 5.00 233 5.25 88 5.50 32 5.75 10.7 6.00 3.4

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SS-DEFINE PHASE

IN THE ANALYSIS PHASE YOU WILL...

Brainstorm on Xs Find change of which Xs affect Y and in what manner Ultimately find which Xs are critical to move the Y in the desired direction IN MEASURE PHASE, WE DEALT WITH Ys. IN MEASURE PHASE, WE DEALT WITH Ys. IN ANALYSIS PHASE, WE WILL DISCOVER IN ANALYSIS PHASE, WE WILL DISCOVER & DEAL WITH Xs. & DEAL WITH Xs.
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SS-DEFINE PHASE

THE FOCUS OF SIX SIGMA

Y = f(X)
Y Dependent variable Output of the process Effect Symptom It is monitored X1, X2,.., Xn Independent variable Input to the process Cause Problem It is controlled

To get results should we focus on Y or X?

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ISI, SQC UNIT, BANGALORE

B e c o m e A w a r e o f th e P r o b le m D e s c r ib e t h e P r o b l e m D e f in e a n d V e r if y R o o t C a u s e s I d e n t if y P o t e n t i a l C a u s e s S e le c t L i k e l y C a u s e s I s t h e P o t e n t ia l C a u s e a R o o t C a u s e ? Y es I d e n t if y A lt e r n a t iv e S o lu t i o n s V e r ify C o r r e c tio v e A c tio n s I m p le m e n t p e r m a n a n t a c t i o n s P reven t R ecu rren ce C o n g r a tu la te y o u r T e a m

SS-DEFINE PHASE

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SS-DEFINE PHASE

Cause and Effect Diagram for High Petrol Consumption

Procedure
Impatience Craze Poor anticipation Wrong gears Wrong culture Poor skill Bad attitude

Driver

Vehicle
Heavy Body Shape Inexperience High H.P Engine Cylinders Spark plugs Contacts Life Technical details Fuel mix Carburetor

Always late Lack of awareness Riding on clutch

High Petrol

Crossings Restrictions One way Circuitous Road No turn Traffic

Spurious Spares Tyres Inferior

Consumption
Impurities Incorrect Octane no.

Road

Frequent Petrol Faulty stops Negligence pressure Speed Breakers Additives Ignorance Potholes Irregular Incorrect viscosity Low pressure servicing Poor Clogged Oil condition filters False Steep Not changed economy Low level

Maintenance

Materials

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SS-DEFINE PHASE

Validation of Causes Validation of Causes

GEMBA (Work Place) Investigation List each cause and verify them through workplace observations.
Causes Bunching of car Specifications/ Desired Observations states 6 out of 10 Maximum 2 at a moments time Remarks May be a potential root cause for Delay in servicing

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SS-DEFINE PHASE

Data Based validation of Causes

CTQ(y) Type
Single Continuous (Noise) Single Continuous (Noise)

Cause(x) Type
Discrete in Two categories (Bearing-1 & 2) Discrete in two categories (Bearing-1& 2)

Question to Answer
Do bearing have any effect on Variation in Noise?

Type of Analysis
2 Variance test (F-test)

Do bearing have any effect on Noise level? Do machine have any effect on Cycle time? Do machine have any effect on variation in Cycle time?

2-sample t-test.

Single Discrete in more Continuous than two categories (Cycle time) (Machine-1,2& 3) Single Continuous (Cycle time) Single Discrete (defectives) Discrete in more than two categories (Machine-1,2& 3) Discrete in two categories (Month -1& 2)

Analysis of Variance/ Analysis of Means Bartletts test for equal variances.

Do time have any effect on defectives? Do type of jobs have any effect on error level?

2-proportions test

Single Discrete in more Discrete than two/more (Error/defect) categories (Type of jobs)

2 test (Chi- square

test)

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SS-DEFINE PHASE

Data Based validation of Causes (Contd.)

CTQ(y) Type
Single Continuous (Cycle time) Single Continuous (Cycle time) Single Discrete (defectives)

Cause(x) Type
Single continuous (Time taken in Process step 1) Multiple continuous (Time taken in Process steps 1,2&3) Single continuous (machine speed).

Question to Answer
Do time taken in process step 1 Influence the cycle time? Which process steps Influence the cycle time maximum? Does the machine speed influence defectives?

Type of Analysis
Simple correlation and Regression analysis. Multiple Regression analysis.
Logistic Regression

Single Single continuous Does the machine speed Discrete (machine speed). influence defectives? (defectives) Discrete in two Single Does the machine speed categories Continuous influence noise level? (machine speed). On same Subject (Noise level at Two different speed)

Multiple Logistic Regression Paired t-test

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SS-DEFINE PHASE

Data Based validation of Causes (Contd.)

CTQ(y) Type Cause(x) Type Question to Answer
Do the supplier have different cycle time?

Type of Analysis
Wilcoxon signed rank test

Single Single discrete in Continuous two categories but non normal (Two supplier) (Cycle time) Single Continuous but non normal (Cycle time)

Single discrete in Do the supplier have different More than two cycle time? categories (Supplier 1,2 & 3)

Kruskal-wallis test

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SS-DEFINE PHASE

IN THE IMPROVE PHASE YOU WILL

Learn, how to select the solution How to pilot the solutions How to assess the risks How to implement the solutions

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GENERATING SOLUTION IDEAS

Review what you know about the process and the verified cause. Brainstorm solution ideas; use creativity techniques. Combine ideas into solutions.

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A PATH TO BETTER SOLUTIONS

In order to get better solutions, we will follow these steps:
Generate Criteria Weight Criteria Evaluate Ideas

The tool we will use for this is the Solution Prioritization Matrix.
Criteria and Weights
Easy Quick Tech Hi Impact Customers

Solution A B C D

0.2 3.0 1.2 2.6 1.2

1.25 10 18.75 13.75 7.5

0.3 2.4 4.2 2.7 2.7

1.65 19.8 18.15 8.25 19.8

0.6 8.4 5.4 4.8 5.4

SUM 43.6 47.7 32.1 36.6

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SS-DEFINE PHASE

WHY PILOT?
Improve the solution Understand risks Validate expected results Smooth implementation Facilitate buy-in Identify previously unknown performance problems
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WHEN TO PILOT
Pilot when: You need to confirm the expected results and practicality of the solution. You want to reduce the risk of failure. The scope of the change is large, and reversing the change would be difficult. Implementing the change will be costly. Changes would have far-reaching, unforeseen consequences.
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EVALUATE THE PILOT

Compare results against the original definition of a defect and against CTQs. Recalculate process sigma and process capability. Analyze causal relationships and process conditions.

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PLANNING GRIDS DEFINITION

A planning grid helps to identify the resources and outcomes for each step in the process.
Step Number Step Deliverable Respon- Due sibility Date
Calvin, Max, Sheryl Maria

Whom to Involve
Dept. staff, Maria Dept. staff

Budget/ Cost

Other Topics

1 2 3 4

Develop new wiring schematic Conduct Changes Revalidate System Update documentation

Wiring Plan Machine Changes Documentation Documentation

6/12

N/A

6/12

N/A

Maria Calvin

6/16 6/8 Other dept supv

N/A N/A

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SS-DEFINE PHASE

PLANNING GRID FEATURES

Steps listed sequentially Outcome of each step clearly identified Person(s) responsible identified
Whom to Involve
Dept. staff, Maria Dept. staff

Step Number

Step

Deliverable

Respon- Due sibility Date

Calvin, Max, Sheryl Maria

Budget/ Cost

Other Topics

1 2 3 4

Develop new wiring schematic Conduct Changes Revalidate System Update documentation

Wiring Plan Machine Changes Documentation Documentation

6/12

N/A

6/12

N/A

Maria Calvin

6/16 6/8 Other dept supv

N/A N/A

Timing and other factors tracked

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SS-DEFINE PHASE

THE PEOPLE SIDE

Too often we spend all our time on the technical side of a changewhat has to happen by when, etc. We ignore the people side of the changehow to help those who will have to change their ways of doing things in order to realize the new change. There are three elements of the people side:
Communication: the exchange of information both from you to others and from others to you. Participation: involving people in the planning and execution of a change so they can develop shared ownership and commitment. Education: providing people with what they will need to know before they successfully implement the desired changes.
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BENEFITS OF PEOPLE-SIDE PLANNING

Increased understanding Increased commitment Increased capability decreased confusion decreased resistance decreased fear of failure

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APPROACH TO CONTROL

Quality Control & Quality Control & Process Change Process Change Management Management

Standardize and Standardize and Document Document Effective Effective Methods Methods

Establish Establish Ongoing Ongoing Project Project Monitoring Monitoring

Evaluating Evaluating Results Results

Hand Off, Hand Off, Summarize Key Summarize Key Learnings and Learnings and Draft Future Plans Draft Future Plans

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CONTROL PHASE
Till now you may have
Described your Y and got the direction of action. Isolated your critical Xs. Optimized the process by deciding on the level of these Xs.

IN THE CONTROL PHASE YOU DEAL WITH HOLDING THE GAINS THROUGH CONTROL OF Xs.
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SOME WAYS TO MAINTAIN/CONTROL YOUR NEW PROCESS CAN BE BY

Standardizing : Put it in audit checklist, quality plan, documented procedure etc. Fool-Proofing : To ensure that it can be done in no other way except how you want it to be done. Have Advance Warning Systems : If something goes wrong, it tells that to you NOW What you would as such come to know of it over a period of time. e.g. : Control Charts
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SS-DEFINE PHASE

PROCESSES CAN BE CONTROLLED BY BUT NOT LIMITED TO

SPC and Advance Warning Systems Inspection & Audits 100% checking of output Fool-Proofing Sampling Plans Control / Quality Plans Quality Systems
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Different processes would be sensitive to different parameters

e.g.: Man, Machine

Hence different processes would require different controls which in turn would depend on that specific parameter to which it is sensitive
e.g.: Brazing may be welder dependent. Hence training would be an important control parameter. Thus leading to concept of brazer qualification.

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IN A NUT SHELL
Your Process may be:
AFFECTED BY Initial Setup Equipment/ machine settings Fixtures Tooling First approvals, monitor the assignable causes Tool approval, Fool-Proofing of mating parts, FPI, Audit checks M an M aterial M aintenance Environment Training and Fool-Proofing Certification before use PM schedules, FPI check after each maintenance Control environment and PM of environment controlling equipment
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CAN BE M AINTAINED BY FPI in between the checks Parameters feedback system

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SS-DEFINE PHASE

CONTROL PLAN
PROTOTYPE PRE-LAUNCH PRODUCTION KEY CONTACT / PHONE : Head, Quality & C.S. DATE (ORI.) : 08.09.99 Page 01 of 02 DATE (REV.) : 27.06.00 CONTROL PLAN NUMBER : CP-M13-02 PART NUMBER / LATEST CHANGE LEVEL : ML PART NAME / DESCRIPTION : Generic CORE TEAM : BSK, HA, GVS, KSK SUPPLIER / PLANT APPROVAL / DATE : 01.10.99 CUSTOMER ENGG. APPROVAL / DATE (IF REQD.) : N.A. CUSTOMER QUALITY APPROVAL / DATE (IF REQD.) : N.A. OTHER APPROVAL / DATE (IF REQD.) : N.A. METHODS PRODUCT / EVALUATION / PROCESS MEASUREMENT SPEC. / TECHNIQUE TOLERANCE SAMPLE SIZE FREQ. CONTROL REACTION METHOD PLAN

SUPPLIER PLANT : Nanjangud SUPPLIER CODE : N.A. OTHER APPROVAL / DATE (IF REQD.) : N.A. PART / PROCESS NAME / PROCESS OPERATION NUMBER DESCRIPTION MACHINE, DEVICE, JIG, TOOLS FOR MFG. CHARACTERISTICS NO. PRODUCT PROCESS SPL. CHAR. CLASS

M13

Drilling

Drilling machines, Drill bits, Aluminium Entry & backup

1 2

Drill hole position Hole quality

* *

+ 50 - X + 50 - Y As per SOP

True measure Cross Section

Every spindle SPC chart Once / week All layer counts Hole quality chart / log book Bottom Every Visual panel lot Visual

Check & adjust Check & adjust

3 4

Hole diameter Hole count Machine setup

As per traveler As per program Scope drill target pad distance

Pin gauge

Check & adjust Check & adjust

Drill check sheet Bottom Every panel stack

As per traveler Scope drill m/c.

All 100% Log book Quarantine panels & adjust previous process

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SS-DEFINE PHASE

POKA-YOKE (JAPANESE TERM) Fail Safe

Methods used to either make the occurrence of a nonconformity impossible or to ensure that it does not pass undetected.

However
As we get better at fool-proofing, we get better fools.
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SS-DEFINE PHASE

STANDARDIZATION
Making sure that important elements of a process are performed consistently in the best possible way. Changes are made only when data shows that a new alternative is better. Documentation is key
Making sure documentation is up to date and used encourages ongoing use of standardized methods.

Discussion
What images come to mind when you think of process standardization?

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BENEFITS OF STANDARDIZATION Standardization helps us compete more successfully in the marketplace by providing:
Increased reliability Reduced costs Improved employee performance Increased safety Processes that remain in control Continuous improvement Flexible practices that allow response to customer needs

for

quick
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STANDARDIZATION = STANDARD PRACTICES AND PROCEDURES A standard practice is A definition of a work method wherein all variables of the method have been specified in detail. It is a written agreement between the worker and the company regarding how the job will be done.
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WHAT DEFINES A STANDARD PRACTICE?

Purpose: To gather technology and process skill in written form and to make it easier for everyone to do their work.
Contents: Written so even workers who are not fully trained can use them easily Specific to the job, written at an appropriate level of detail Describe how to prevent variation Provide clear instructions Considered priorities
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SS-DEFINE PHASE

TRAINING
When you have completed the documentation, you need to make sure that everyone using a common process is trained in the new methods. Even experienced employees need to be trained in the new methods.

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SS-DEFINE PHASE

SHEWHART CONTROL CHARTS

It is an important tool to give advance warnings about the drift from the normal behavior.

To draw control charts, for a process we need to know the average and obtained from the process. standard deviation

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Before

SS-DEFINE PHASE

DISPLAYING BEFORE & AFTER DATA

After
Good

Add more data to existing run chart control chart.

an or
Before

}Improvement
} Remaining Gap
Step 4 changes implemented Target

Prepare new Pareto charts for those you created in Step 2. Make scale and dimensions the same so you can more accurately judge degree of improvement. Draw new frequency plots on the same scale as the original plots.

After

}
A1 A2 A3 A4

Improvement

A2 A1 A3 A4

Before

After

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RECALCULATE PROCESS SIGMA

Step Units 1 2 3 4 5 6 7 8 9 10 11 12 40 40 40 40 40 40 40 40 40 40 40 40 Opportunities 2 x 40 = 80 1 x 40 = 40 3 x 40 = 120 1 x 40 = 40 4 x 40 = 160 1 x 40 = 40 2 x 40 = 80 4 x 40 = 160 1 x 40 = 40 2 x 40 = 80 2 x 40 = 80 1 x 40 = 40 960 BEFORE 61 37 113 34 142 38 69 143 37 64 72 35 846 AFTER 17 1 12 0 8 0 3 37 0 5 2 1 86 AFTER 86 960 BEFORE

Yield

= 1

846 960

= 1 .88 = 12% Sigma = 0.3

Yield

= 1

= 1 .09 = 91% Sigma = 2.8

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