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Six Sigma

-:
) (Six Sigma
1986
. ) (Six Sigma


3.4
).(Six Sigma
) (Six Sigma


2.

Statistics Analysis using Six Sigma Methodology

Abstract
Six Sigma methodology is a recent subjects,It was first put into
implementation at Motorola in 1986,but it's now widely used by most
large corporations.The Six Sigma methodology is an place to use
statistics tools,Collect data,Analyze and diagnostic the variation in
productivity. Is it randomly process or significant event?, and then to
tracking productivity in all phases and continuous controls production
and process to ensure reduce variations, and to access to 3.4 defects
per million Opportunity, this point it is the target .
In this research we display the Six Sigma methodologies in each
Historical and Ideology, and giving importance to some Statistics tools
by set of application examples and illustration graphing, and
proposition to implementation this methodology in higher education
with specialized in department of statistics and informatics, which
appeared the sigma of department is around 2 sigma.

-:
) (Six Sigma

) (process management
.
)(Six Sigma
.

674






.
.

.

.
.


.


.




.


.
) (Six Sigma
).(Six Sigma

-:

) (OLS) (Ordinary Least Squares )(1700

) Statistical Process
(SPC) (Control ) (W. Shewhart 1924
) (Bell Laboratories ) (X-Bar )(R
) (Shewhart

. ) (George Box ) Genichi
(Taguchi
) (Edward Deming
675

 ) (TQM) (Total Quality Management

. ) (TQM
).(Allen,2006,15-16
.


.
)-:(Six Sigma
) (Six Sigma
) (Six Sigma





.

)-:(Six Sigma
1979 ) (Six Sigma
) (Motorola


) (Six Sigma ) Six
(SSA) (Sigma Academy )(Mkel Harry 1995
) (GE) (General Electric ) (SSA
) (Six Sigma
) (GE .


).(Levine,2006,2

)-:(Six Sigma

) Critical To
) (CTQ) (Quality (


.

676




.


-:
N

2
) (x i

i =1

-:
: .
-: .
-: xi .
-: N ) .(30
30 -:
n

2
) (x i x

i =1

n1

=s

-:
-: s .
-: x .
-: xi .
-: n .


.

) m
( ) .(

) ( ) ( 2 -:
1 x 2
(
)
2

-:

677

1
2 2

= )f (x

 )(1

.(Joglekar,2003,25):
)(1
)*(

sigma

697.672

2
308.770
3
66.811
4
6.210
5
233
6
3.4
)(1 68.27% ) (
31.73%
) ( .
95.46% ) ( 2 99.73% ) .( 3
) (Deffect unit ) (
) (697.672 ) ( 2 ) (308.770 ) ( 3 ) (66.811
) ( ) .(1
------------------------------------------------------------------------------------------)*( ) (Opportunity .

)(99.73% )(2009

)
(

678

 )

( ) (392008

) (99.99966% )(0.0034%
) (3.4 ).(Six Sigma
) (Six Sigma
) (Principles ) (Techniques

) (Pyzdek,,2003,3


)(Sanjay Kumar
) .(472008
.

)(Six Sigma
.
(a )-:(Unit
).(Six Sigma
(b )-:(Defective Unit
.
(c ) -:(DPU) (Defects per unit
) (n -:
No. of Defects
= DPU
No. of Units
50 ) )((Unit
10 ).(DPU=10/50=0.5
(d )-:(Defect Opportunity
4
12 .
(e ) -:(DPO) (Defects per opportunity
-:
Deffect
= DPO
No. of Opportunity
)(50 ) 10(
) 3( ) .( DPO = 10 /( 50 3) = 0.0667
(f )-:(DPMO)(Defects per Million opportunities

DPMO = DPO 106

.
679

 ) (e ) .( DPMO = 0.0667 106 = 66700

(g )-:(Y)(Yield
. 25 20
).(Y=(20/25) 100=80%
(h )(Rolled Throughput Yield
) -:(RTY ) (sub process
RTY = Y1 Y2 ... Yk
-:
) (Y ) (k
3 ) (Y1=0.997
) (Y2=0.995 )(Y3=0.897 ).( RTY = 0.997 0.995 0.897 =0.8898
(i )-:(Six Sigma Level
).(Breyfragle,2003,189) (Six Sigma
)Sigma Equality Level = 0.8406 + 29.37 2.221 ln( DPMO
) (f ) (3.00865 )(99.74%
) ( ) (0.26%
) ( ).(2
)(2

Distribution Plot
Normal; Mean=0; StDev=3.00865
0.14
0.12
0.10

0.06

Density

0.08

0.04
0.02
0.0013
9.06

0.0013
0.00
-9.06

0
X

)----(
-: DMAIC (Analyze-Improve-Control

)Define-Measure-

) (Six Sigma )Define-Measure-

((DMAIC) (Analyze-Improve-Control )(
) (Six Sigma
680

 )(
)-:(Park,2003,37
(a)-:(Define
)(
.
(b )-:(Measure
)(Dependents variables

)-:(Basu,2009,65
).(Histograms
).(Run Charts
).(Scatter Diagrams
).(Cause and Effects Diagrams
).(Pareto Charts
).(Control Charts
).(Proces Capability Measurement
(c )-:(Analysis

).(Regression Analysis
(d )-:(Improve


. ) Six
(Sigma
.
(e )-:(Control

) ).((Gantt Chart

.

-:


.

.
681

 .

. 24
4

.
-:

(a )-:(Stratified sampling



)
( .

(b )-:(Cluster Sampling

.

(c )-:(Systematic Sampling
) (Pattern

1 9

).(1041977

-:
(a -:Histogram


).(Basu,2009,67-68 ) (3
) (Capability
).(Tolerance

682

 )(3

.(Kumar,20):

(b )-:(Run Charts

) (Trend )(Cycles
.
) .(Basu,2009,70 -:
)(4

R un C ha r t of C 2
70
60

C2

50
40
30
12

11

10

9
8
7.7
2
0.598
0.402

6
7
O b s e r v a t io n

N u m b er o f r u n s u p o r d o w n :
E x p ec ted n u m b e r o f r u n s:
L o n g est r u n u p o r d o w n :
A p p r o x P - V a lu e fo r T r en d s:
A p p r o x P - V a lu e fo r O sc illatio n :

4
7
5.5
4
0.895
0.105

N u m b er o f r u n s a b o u t m e d ia n :
E x p e c te d n u m b e r o f r u n s:
L o n g e st r u n a b o u t m e d ia n :
A p p r o x P - V a lu e fo r C lu ste r in g :
A p p r o x P - V a lu e fo r M ix tu r e s:

.
683

 ) (8
.
).(1272008
(c )-:(Scater Diagrams

. )(Regression Analysis
) (Pattern )
( )(.
)(5

)Scatterplot of Miles per gallon vs Weight(ib
35

30

20

Miles per gallon

25

15

3600

3400

3200

2800
3000
)Weight(ib

2600

2400

2200

10
2000

) (5 ) (Milles per gallon,Weight

)(Weight
).(Milles per gallon

(d )-:(Cause-and-effect diagram
) (Ishikawa diagram ) fishbone
.(diagram
)(
.

)( )) (5M1E (
).(Park,2003,74

684

 )(6

)(

(e )-:(Pareto Analysis

) (20-80 ) (80%
)) (20%. (125 )(bar

)(Vital few
)(Trivial many
.
. ) (7 )(Pyzdek,2003,260
) (Rotten ) (Bruised
80% .

685

 )(7

Pareto Chart for Problem
450

100

400
80

350

60

250
200

40

Count

Percent

300

150
100

20

50
0

0
er s
Ot h

19
4.3
100.0

z ed
r si

d
ise
B ru

de
Un

100
22.7
76.0

87
19.7
95.7

n
tte
Ro

235
53.3
53.3

Defect
Count
Percent
Cum %

(f )-:(Control Charts
) (Six Sigma

)(SPC
) (Control Charts
.

.





.


.

).(185-1891977
)
( )(levels of the samples
) (Upper Center Line, Lower Center Line
)(UCL,LCL ) (CL) (Center Line
) (UCL,LCL

686


. .
y ) Critical To
(CTQ) (Quality ) ( y ) ( y
) (UCL,CL,LCL )-:(Bass,2007,148
UCL = y + k y
CL = y
LCL = y k y
k y ) (CL )(UCL,LCL k y

y .
) (8
6 ) (Outlier
.
)(8
x-bar

X-bar Chart for C1

8.5

1
UCL=8.054

7.5

5.5

Mean=5.5

4.5

Sample Mean

6.5

3.5
LCL=2.946
2.5
6

Sample Number

.

.

687

 )(P-Chart

.
.


).(200-2031977

.
)(Bass,2007,15-16
) (Six Sigma ) (3.4 ).(DPMO
(g )-:(Flowchart

.
.
).(Pete P. & Larry H.,2002,53
(h )-:(Process Capability Measurment

)(Sleeper,2006,319
.
).(Improvement

) (Cp)(potential process capability index ) process
.(Cpk) (capability index
)-:(CP
))(specification width
(
)( 6 ) (process spread -:
USL LSL
= CP
6
) ( 6 )(CP )
( ) (CP ) (CP<1 )
( )
( ) (CP ) (CP>1
) (. ) (CP=1
) (2700
).(Bass,2007,177

688

 )-:(Process Capility Index

) (target(T
-:
) C Pk = C P (1 k
-:
) t arg et(T) Pr ocess mean(
=k
1
) ( USL LSL
2
K=0
(Park,2003,21-22) CPk=CP ) (k
) (k )
( .

CPk -:
Pr ocess mean( ) closer specification Limit from
= C Pk
)(1
3
)) (CPU) (Upper Capability Index
) ( )(Upper Tolerance Spread
) (( 3 )(Lower Capability Index
)) (CPL ) (
) (Lower Tolerance Spread ) (( 3 -:
USL
LSL
= CPU
,
= CPL
3
3
) (1 ) (CPU,CPL-:
)CPk=min(CPU,CPL
) (CPk=1
) ( C Pk > 1
) (CPk<1 .
) (CP ) (CPk -:
) ( = T ) (USL-LSL= 6
) (3 )(CP=1 ) ( ) ( 3
) ( 3 ) (CP -:
Sigma level= 3 C P
689

 ) (
) ( 1.5
. ) ( 1.5 )(CPk=1
) ( 3 + 1.5 = 4.5 ) (CPk
)-:(Park,2003,20
Sigma level = 3 C Pk + 1.5

)= 3 (C Pk + 0.5
) (CP ) (CPk -:

CPk=CP-0.5

-:
= 16 , = s = 2 , USL = 20 , LSL = 10
-:
USL LSL 20 10
= CP
=
= 0.83
6
6 2
LSL USL
,
C Pk = min

3
3
16 10 20 16
,
= min

6
6

2
= min ,1 = 0.67
3
) (CP
) (CPk .

-:

(a )-:(Correlation Coefficient

) 1- .(1+ -
1 1+
. -:
) ( x i x )( y i y
=r
2
2
) (x i x) (y i y
(b )-:(Regression Analysis
1+ 1-

.
.

690

 ) Ordinary
.(OLS) (Least Squares
-:
Y = 0 + 1x +
-:
-: 0 .
-: 1.
-: .

).(Multiple Linear Regression

-:
)-:(Gantt
.


) ) ((9
).(Breyfogle,2003,950
)(9

)-:(Six Sigma
) (Six Sigma

.
) (Six Sigma
3.4

691


.
) (Six Sigma





.

-:
) (
2008-2004
) (Six Sigma -:
.
) ( .

.
.

.
)(2
/
2008-2004

2.32137 206185 0.206 0.339

97
20
59
2005-2004
2.17937 246913 0.247 0.37
81
20
54
2006-2005
1.72009 390625 0.390 0.46
64
25
54
2007-2006
2.18768 244444 0.244 0.50
135
33
65
2008-2007
2.15131 255319 0.255 0.41
94
24
58

) (2 2

.
) (X

.

692


) n) (ai , i=1,,n ( ).(12-10
)(10

Boxplot
|
|
|
|
|
|
+-----+
|
|
|
|
**-----
| | +
|
|
|
|
|
|
+-----+
|
|
|
|
|

#
1
3
2
3
2
3
3
3
6
6
7
2
1
1
3
2
5
1
3
2

Stem
9
9
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
0
0

Leaf
6
012
68
112
79
013
578
122
556679
001144
5677889
44
7
3
668
14
55666
1
888
00
----+----+----+----+
Multiply Stem.Leaf by 10**+1

) (10 ) (X 96
) (+
)(Anderson-Darling test
) (0.626
)(0.098
).(11
)(12 50 )
50 (.
)(11

Normal Probability Plot

.999
.99
.95

.50
.20

Probability

.80

.05
.01
.001
100

50

X
Average: 49.4237
StDev: 25.8585
N: 59

Anderson-Darling Normality T est

A-Squared: 0.626
P-Value: 0.098

693

 )(12

100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0

100

95

90

85

80

75

70

65

60

55

50

45

40

35

30

25

20

15

10

degree

).(3
)(3
/

1.49014
457627.118
27
59
X
1.77695
372881.355
22
59
X1
1.49014
457627.118
27
59
X2
2.09919
271186.44
16
59
X3
1.72266
389830.508
23
59
X4
2.15490
254237.288
15
59
X5
1.93712
322033.898
19
59
X6

) (3 2


.

) (Six Sigma -:
) (Six Sigma

694

695

-:
.1 ) (Six Sigma
3.4
).(Six Sigma
.2 )(Six Sigma



.
.3 )(Six Sigma .
.4
2
).(Six Sigma

696


-:
Six " 2009 .1
93 31 " Sigma
.
Six Sigma"2008 .2
. " :
. "" 1977 .3

-:
1. Allen,Theodore T.,2006, Introduction to Engineering Statistics and
Six Sigma , Springer-Verlag London Limited.
2. Breyfogle, Forrest W.,2003,Implementing Six Sigma,Smarter
Solutions Using Statistical Methods2nd ed., John Wiley & Sons, Inc.,
Hoboken, New Jersey,USA.
3. Bass,Issa,2007,Six Sigma Statistics with Excel and Minitab,
McGraw-Hill Companies,Inc..
4. Basu,Ron,2009 Implementing Six Sigma and Lean:A practical
Guide to Tools AND Technigues ,Butterworth-Heinemann is an
imprint of Elsevier Linacre House, Jordan Hill, Oxford OX2 8DP,
UK.
5. Joglekar,Anand M.,2003;Statistical Methods for Six Sigma, John
Wiley & Sons, Inc., Hoboken, New Jersey.USA.
6. Levine, David M.,2006, Statistics For Six Sigma Green Belts With
MINITAB and JMP, Pearson Education, Inc.,New Jersey, USA.
7. Park, Sung H.,2003, Six Sigma for Quality and Productivity
Promotion, Asian Productivity Organization.
8. Pete P. & Larry H.,2002, What is Six Sigma? ,McGraw-Hill
Companies,Inc..
9. Pyzdek,T.,2003,The Six Sigma Handbook,Revised and Expanded,A
Complete Guide for Green Belts,Black Belts,and Managers at All
Levels,McGraw-Hill Companies,Inc..
10. Sleeper, Andrew D.,2006, Design for Six Sigma Statistics,
McGraw-Hill Companies,Inc..
-:
1. Kumar,Sanjay,Six Sigma Green Belt Training, Indian Statistical
Institute New Delhi 110016, www.scribd.com/doc/6425835/SixSigma-Green-Belt.

697