SIX SIGMA

Six Sigma

-2-

6
.
-

GE Jack Welch

-3-


Six Sigma
1980 ( )

- 1970
- Bob Galbin
Michel Harry
-

Motorola
six sigma
1990 Six Sigma Institute
data
six sigma
-4-

 Six Sigma
Motorola

TI

GE

SONY

1987

1988

1995

32/

1988 : 30 %
1993 : 7.4%

38/

2000
2000 Black
Belt

Top Down

(4 100 )

-5-

1997

 Sigma

Sigma
Sigma () .
Sigma ,
Sigma DPU(Defect Per Unit), PPM(Parts Per Million)
.
Sigma
.
Sigma , Cycle-Time
, .

-6-

PPM

3.4

233

6,210

66,807

1 340
1 1.8

1.5
1 670

308,537

1 24

-7-

 Six Sigma (1)

100 3.4
.
()
-
-
-
-
- ~
-8-

 Six Sigma (2)

input

process

output

-9-

 Six Sigma
Business Strategy

Statistical Measurement

6
6

-6 -3

+3 +6
1/2
spec

Philosophy

Dr. Michel Harry

- 10 -

 Six Sigma (1)

1)
, .
.

2) Tool
, , , Biz. System
Full Package Tool.

3)
.
Process Target /

4)
Loss .
.
- 11 -

 Six Sigma (2)

(Metric)
(Metric)

Benchmarking
Benchmarking
Vision
Vision

(Philosophy)
(Philosophy)

(Method)
(Method)

(Tool)
(Tool)

(Symbol)
(Symbol)

(Goal)
(Goal)

(Value)
(Value)

- 12 -

 Six Sigma Process

: Needs CTQ , CTQ

Process Tolerance , Process CTQ
Six Sigma
: / , , Neck ,
point

: - : loss
- : Defect Free

: - CTQ (QFD ), ,
Process mapping,Brain storming ,sampling
FMEA, , ,3why,DOE, , , SPC

- 13 -

 Six Sigma
6 , Business System Tool

Needs Meet CTQ
Tolerance

CTQ

S/W Field

I.T Real Time Monitoring

Output

( , lead time)
Focusing

- 14 -

 Six Sigma (1)

Q- ( )
F-Cost
Lead Time

er
m
o
t
s
u
Total C
tion
c
a
f
s
i
t
a
S

Process
Process six
sixsigma
sigma
(3.4PPM)
(3.4PPM)

/
//
/

Six
Sigma
Six Sigma

/
Six
Sigma
SixSigma

- 15 -

/
/

Six
Sigma
Six Sigma

/SVC/
/SVC/

Six
Sigma
Six Sigma

 Six Sigma (2)

66 Quality
Quality

Reliability
Reliability
Life Time
MTBF

A/S

Total
Total
Cost
Cost
Reduction
Reduction

Productivity
process

Total
Total
Cycle
Cycle Time
Time
Reduction
Reduction
Lead Time
Cycle Time

Total Customer Satisfaction

- 16 -

 Six Sigma (1)

Focusing Point
CTQ(Y) = F(X1, X2, X3, . Xn)
Y

Output

Input

6 System
Cost Impact ,
CTQ , CTQ
6 .

6 CTQ

(X1, X2 ) Focusing .

CTQ(Y) X 20%,
80% .
- 17 -

 Six Sigma (2)

.

,

- 18 -

 Six Sigma (3)

.
.
Q.C.D. .
Q.C.D. .
.
.
.
.

- 19 -

- 20 -

 (1)

- 21 -

 (2)
Needs (1)
.

Mega-Competition

Product

Good Product

Value

Cheaper Price

Specialties

Better Quality

Satisfaction

Efficiency -

Effectiveness -
Efficiency -

Productivity -
Productivity -

- 22 -

Effectiveness -
Efficiency -

 (3)
Needs (2)
.

(Volume)

(Value)

(Cheaper)

(Wants)

(Standard)

(Variety)

(Efficiency)

(Effectiveness)

(Productivity)

(Creativity)

- 23 -

 (4)
(1)
.

Value

Price

Cost

Skill

- 24 -

 (5)
(2)

(Knowledge) - -

(Vitality)

- -

- 25 -

 (6)


.

( , ,
CALS )
.

- 26 -

Six Sigma

- 27 -

 Six Sigma (1)

() (4)
.
.
.
.
()
10% ~ 25% .
ZERO 100
.
ZERO .
5 ~ 10% ,
.

- 28 -

 Six Sigma (2)

6
5%
3.4 PPM (Defect)
Process (Defect)

---

99%

- 29 -

 Six Sigma (1)

99% 6

99% GOOD(4.0)

99.99966% Best(6)

- 20,000

- 7

- 5,000

- 1.7

- 2

- 5 1

- 200,000

- 68

- 7

- 34 1

- 30 -

 Six Sigma (2)

PPM
1,000,000
100,000
10,000
1,000
100

Lot

Best-in-Class

10
1
1

(0.43PPM)

Sigma
- 31 -

 Six Sigma (2)

PPM

S ig ma

0.000003

1/8

0.002

0.57

63

30
1

45

2,700

1
1.5

45,600

1
25

317,400

1
170

- 32 -

 Six Sigma (3)

Sigma

6
5
4
3
2

( PPM )

( )

3.4

70

1%

233

30

10 ~ 15%

6.210

10

15 ~ 20%

66.807

20 ~ 30%

308.537

30 ~ 40%

/ 5200

Defects-free
Defects-free
100
100

,
,

10

10

- 33 -

 Six Sigma (4)

Sigma
level
level

PPM
PPM

0.67

308,537

69%

1.0

66,807

93.3%

1.33

6,210

99.3%

1.67

233

2.0

3.4

99.98%
99.9997%
1.5 shift

- 34 -

 Six Sigma (5)

6 :

process()
5 Sigma

Process
4 Sigma

3 Sigma

- 35 -

 Six Sigma (6)

Target

Target

( T )

T
US
L

T
US
L

USL

USL

USL

USL

( )

- 36 -

 Six Sigma (7)

DPU (Defects Per Unit)

DPO(Defects Per Opportunities)
DPMO(Defects Per Million Opportunities)
Sigma Level( Z)
RTY(Rolled Throughput Yield)

- 37 -

 Six Sigma (7)

D = Defect ( )
,

) Claim
U = Unit
Item
) Claim
OPP = Opportunity
/
DO = Defect Opportunity
Defect
) Claim
- 38 -

 Six Sigma (8)

DPU
DPU

Defects Per Unit : Unit Defect

Process 6
.
) Claim 10 , 2
, DPU = Defect/Unit = / = 2 / 1 =2

DPO
DPO

Defects Per Opportunity : Unit Unit

Defect
, ( ) Unit
Defect .
) 1(Unit) Claim 10 , 2
, 2 Defect / (1 Unit 10 Opportunity = 0.2 , DPO=0.2

DPMO
DPMO

Defects Per Million Opportunity : DPO 1,000,000

6 PPM(Part Per Million) Scale .
) DPMO = 0.2 DPO 1,000,000 =200,000

- 39 -

 Six Sigma (9)

1 Set(12) . .
1

D = 35

U = 30
OPP=12

DPU = 35 / 30 = 1.167
12

TOP = 30 12 = 360
DPO = 35 / (3012) = 0.0972
P(ND) = 1- 0.0972 = 0.903
12

18

Yrt = 0.903
1

20

10
- 40 -

= 29.39%

 Six Sigma (10)

DPMO Sigma
DPMO
DPMO

Sigma
SigmaLevel
Level

DPMO
DPMO

Sigma
SigmaLevel
Level

500,000
500,000
460,000
460,000

1.5
1.5
1.6
1.6

17,900
17,900
10,700
10,700

3.6
3.6
3.8
3.8

421,000
421,000
382,000
382,000

1.7
1.7
1.8
1.8

6,210
6,210
3,470
3,470

4.0
4.0
4.2
4.2

345,000
345,000
309,000
309,000

1.9
1.9
2.0
2.0

1,870
1,870
968
968

4.4
4.4
4.6
4.6

242,000
242,000
184,000
184,000

2.2
2.2
2.4
2.4

483
483
233
233

4.8
4.8
5.0
5.0

136,000
136,000
96,800
96,800

2.6
2.6
2.8
2.8

108
108
48
48

5.2
5.2
5.4
5.4

66,800
66,800
44,600
44,600

3.0
3.0
3.2
3.2

21
21
88

5.6
5.6
5.8
5.8

28,700
28,700

3.4
3.4

3.4
3.4

- 41 -

6.0
6.0

,,
,
S i x Sigma
TQM

( )

R&D

I S O 9 0 00
TQC

( )

( )

QC ( )

30 ~50

6 0~7 0

80

90

- 42 -

(Bottom-Up )

(T o p - D o w n)

( 6 )

QC 7

( B S C)

- 43 -

COPQ
(Cost of Poor Quality)

- 44 -

 (1)
Cost of Poor Quality(COPQ)

( )

Long cycle time

( , )

- (COQ) : 5%
- : 50%
- 45 -

 (2)

Hidden
Hiddenfactory
factory

Hidden factory ,
, /
15~40% .
: AV Feigenbaum Total Quality Control 3rd Ed., Revised, McGraw-Hill., 1991

- 46 -

 (3)
Six Sigma
%
25

20

Cost of failure

15

( )

10~15%

5
(GE)

10
5

10%

6
( )

Sigma

233

6210

4
- 47 -

66807
PPM
3

308537

500000

 (4)

( )

2.5%

5.0%

4.5%

15.0%

7.5%

20.0%

12.0%

/ 27.5%
()

30.0%

, 500
P. .

20% .

%
30
25
20
15

10
5

Sigma

- 48 -

233

PPM

66807
500000
308537
4
3
2
1

6210

 (5)

(%Sales)

GE 6sigma

30

40
.

25

20

$6.6B

15

10
$2.8B

5
0
SIGMA

3
6

233
5

6210
4
- 49 -

66,807
3

308,537
2

500,000
1

(Customer)
1. () ,

2.
(Satisfaction)
1. ;
2. ,, ;
3.
From Vision of Six Sigma
- 50 -

 CTQ
CTQ(Critical To Quality)

1. /

2.

) / =
CTQ : (), ,
CTQ : , ,

- 51 -

 /
Manufacturing Transactional
Transactional

Manufacturing

Focusing

Focusing

Tool

Tool

Data Mix

Data Base

Approach

"Y" Focusing

"X" Control

Output

Output

Cycle Time Reduction/

Accuracy Improvement

Process Optimization

Process

Process

- 52 -

Six Sigma
(D-M-A-I-C)

- 53 -

 6 Sigma

?


?

?

?

?
.
- 54 -

 (1)

A :

B :

A B ?
( : , , .)
- 55 -

 (2)

A :

B :

A B ?
( : .)
- 56 -

 (3)
S T AR T

A :

B :

F IN IS H

A B ?
( : . ?)
- 57 -

BTS- (Breakthrough Strategy)
- 58 -

 Process

Define
Business issue

Control

-
-

Make it
stick

Base line

- Process
- Monitoring system

Implement
- Action plan
-

Improve

-
-

Root cause

- Narrow
down Vital few

Analyze

- 59 -

Measure

 D-M-A-I-C
Define
,
Y(CTQ) Process ,
Project

:
1.
2. CTQ
3. CTQ Process
- 60 -

 D-M-A-I-C
Measurement
Y

:
1. Y
2.
3. Subgroup Plan
4. /

5. (Y) 4-Block Diagram
- 61 -

 D-M-A-I-C
Analysis
Y
X
Vital Few
:
,
1.
X Y .
2. ,
.
3. ,
.
- 62 -

 D-M-A-I-C
Improvement
, X
Vital Few ,
Process optimization

:
1.
2.
3. Guideline

- 63 -

 D-M-A-I-C
Control
, ()
Process ,

:
1.
2.
3. &
4. Procedure) &
5. Audit
- 64 -

 Tool

Define

Y
- QFD / FMEA

- Process Mapping

- Goal Tree

Measurement

Y
-Y

- Process Mapping

- Gage R&R

-
- Brainstorming

- 65 -

 Tool


Analysis

X
- Graph Analysis

- Regression

- QC 7 Tool

Improvement

X
-

- Brainstorming

- Benchmarking

- 66 -

 Tool


Control

- Control Plan
- Training & Audit
- Process Monitoring System

- 67 -

Six Sigma

- 68 -

 Six Sigma (1)

Top
TopDown
Down

- -

ex)
G.E

ex) G.E
- -Top
Top

,
,

,
,

Message
Message

- -

, ,

Process

Process
- -

R&D
R&D

(Transaction)
(Transaction)

66

- -

(CTQ,
(CTQ,,
,Cp
Cp) )
- -6
6

- -

,
- -Project
Project

- 69 -

 Six Sigma (2)

- -

,
,

CTQ
,
Impact

.
CTQ , Impact .

Program
Program

- -

- -

- -

(Infra)
(Infra)

- -Project
Project

Infra
Infra

- -,

,
- -

System
System

.
.

.
.

- 70 -

 Six Sigma (3)

Top
,

Project
System
,

Project
,

RIGHT INFRA (,,)

- 71 -

 Six Sigma (1)

( , )

(, )

(
(

) )

(
(

)
)

6
6

10

10

1
1

(, )

- 72 -

 Six Sigma (2)

Belt ?

Champion

Background 6skill ,
Project

Belt ?

Master Black Belt

, Project
/.

Black Belt
Green Belt

6 ,
Project Skill .
Project .
Project / Champion
Feedback.

Belt
Belt Project
Project

6
6

.
.
- 73 -

 Six Sigma (3)

Champion ?
, 6 .

Champion ?
MBB(6 ) ,
Commitment .
6 , /
.
BB( 6 Leader) Project .
Process F-Up Monitoring
, Ownership .

Project
Project

.
.
- 74 -

 Six Sigma (4)

MBB, BB, GB Belt , 6
.

Master
Black Belt

Role

6 Technique Leader

BB/GB

Project 4 ( )

Background

Project Drive

Project 5

Skill

Black Belt

Neck

Project

Neck Project 2

Full Time Project

Leader

( )

Tool

Project 1

Green Belt

Neck
Part Time Project

Project
Leader

- 75 -

1 1Project 2

 Six Sigma (4)

1) Grand Champion
6
(//)
MBB

2) Champion
/ 6
6
/CTQ

Owner Champion() Owner

3) MBB, BB ()
Project () ,
/

- 76 -

 Six Sigma (5)

4) Project (GB)

Project
Project /
Project Member
Project Member Project

5)

CTQ
,
(Grand Champion)

Best Practice ,
BB

6) Project Audit
Project
Project /

- 77 -