6

SIX SIGMA

:
1429 2008-



Six Sigma

-Six Sigma -




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.

1992
1993
1996



Six
Sigma
.
012 7438220.

Email:Osama.Abdelaziz@EMCEG.com

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"

6 .........................................................................................................
16 ...............................................................................................
.1 16 ...............................................
.1.1
.1.2
.1.3
.1.4
.1.5
.1.6
.1.7
.1.8
1.9.
1.10.
.1.11
.1.12

16 ..................................................................................................INTRODUCTION
19 ...................................................... QUALITY AND ITS PILLARS
20 ............................... SIX SIGMA AND QUALITY HISTORY
24 ....................................... SIX SIGMA SUCCESS STORIES
25 ...................... SIX SIGMA AND TRADITIONAL QUALITY
28 ...................................................................................... WHAT IS SIGMA
29 .................................................... PHYSICAL MEANING OF SIGMA
?36 .................................................................. WHY SIX SIGMA
37 ........................................................................ SIX SIGMA GOALS
39 .............................................................. SIX SIGMA BENEFITS
40 ................................................SIX SIGMA INFRASTRUCTURE
44 .............................................................COST OF POOR QUALITY

49 ..............................................................................................
2. 49 ....................................................
.2.1
2.2.
2.3.
2.4.
2.5.
2.6.

49 ..................................................................................................INTRODUCTION
50 ..................................................................... "DEFINE" PHASE
53 ........................................................................ "MEASURE" PHASE
55 ................................................................................. "ANALYZE" PHASE
57 ................................................................................. "IMPROVE" PHASE
"59 ..................................................................... "CONTROL" PHASE

62 ..............................................................................................
3. 62 ......................................................................
.3.1
.3.2
.3.3
.3.4
.3.5
.3.6
.3.7

62 ..................................................................................................INTRODUCTION
62 ......................................... SIX SIGMA PROJECTS CATEGORIES
63 .......................................... SIX SIGMA PROJECTS FOCUS
63 ........................ SIX SIGMA PROJECTS CHARACTERISTICS
64 ......................................... SIX SIGMA PROJECT SELECTION
/ 66 ... SIX SIGMA PROJECTS SUCCESS/ FAILURE REASONS
67 ................................. EXAMPLES OF SIX SIGMA PROJECTS

70 ..............................................................................................
4. )( 70 ...............................................................
.4.1
4.2.
4.3.
4.4.
4.5.
4.6.
6

70 ..................................................................................................INTRODUCTION
76 ............................................................... PROCESS VARIATION SOURCES
79 ...................................................... VARIATION SOURCES ANALYSIS
82 .................................. STRATEGY FOR VARIATION MANAGEMENT
84 ..................VARIATION AND EARTHQUAKES ANALOGY
87 ........................................................................PROCESS SHIFTING

90 ...........................................................................................
5. 90 .........................................................................
.5.1
5.2.
.5.3
.5.4
.5.5
.5.6
.5.7
.5.8
.5.9

90 ..................................................................................................INTRODUCTION
92 ....................................................................... CONTROL CHARTS
93 ............................................................ TYPES OF CONTROL CHARTS
95 .......................................................... BENEFITS OF CONTROL CHART
96 ................................CONTROL CHARTS CHARACTERISTICS
100 ..................................... CONTROL CHARTS INTERPRETATION
101 .............................. CONTROL CHARTS CONSTRUCTION STEPS
105 ............................................... ACCURACY OF CONTROL CHARTS
106 ................................................ EXAMPLES ON CONTROL CHART

116 .........................................................................................
6. 116 ................................................................................
.6.1
6.2.
6.3.
6.4.
6.5.
6.6.
6.7.
.6.8

116 ................................................................................................INTRODUCTION
120 ............................... GAGE RESOLUTION / DISCRIMINATION ANALYSIS
) ( 120 ...................................... GAGE BIAS (INACCURACY) ANALYSIS
121 .................................................. GAUGE LINEARITY ANALYSIS
125 ................................................... GAUGE STABILITY ANALYSIS
125 ......... REPRODUCIBILITY AND REPEATABILITY ANALYSIS
134 ................................................ MEASUREMENT SYSTEM INDICES
135 ................................................... GUIDELINES FOR MSA

137 ...........................................................................................
7. 137 .................................................................
.7.1
7.2.
7.3.
.7.4
.7.5
.7.6
.7.7
.7.8
7.9.
.7.10
.7.11
7.12.

137 ................................................................................................INTRODUCTION
138 ............................... DEFECTIVE AND YIELD MEASURES
)140 ................. DEFECTS PER MILLION OPPORTUNITY (DPMO
142 ............................................................................... PROCESS GOODNESS
"144 ....................... SHORT TERM PROCESS CAPABILITY "CPK
"" "145 .. LONG TERM CAPABILITY / PERFORMANCE "PPK
146 ..... DIFFERENCES BETWEEN CAPABILITY AND PERFORMANCE
147 ..... GUIDELINES FOR PROCESS GOODNESS CALCULATION
147 .......................................... SIGMA LEVEL DETERMINATION
149 ................ EXAMPLES FOR PROCESS GOODNESS CALCULATION
160 ........................... COMPOUND PROCESS PERFORMANCE
161 ....................... COMPARISON BETWEEN SIGMA MEASURES

162 ............................................................................................
8. 162 ...................................................................
162 ................................................................................................INTRODUCTION
.8.1
162 .. PRECAUTIONS FOR NON NORMAL DATA TREATMENT
.8.2
THE RELATIONSHIP BETWEEN
.8.3
163 ..............................................................................STATISTICAL TREATMENT & DATA TYPE
)( 164 ................................ TESTS FOR NORMALITY
.8.4
165 ............... NON-NORMAL DATA TREATMENT METHODS
.8.5

183 ...........................................................................................
.9 183 ..........................................................
.9.1
9.2.
9.3.
9.4.
9.5.
9.6.
.9.7
.9.8
9.9.
.9.10
9.11.
.9.12
9.13.
9.14.
.9.15
9.16.
9.17.
9.18.
.9.19
.9.20
.9.21
9.22.
9.23.
.9.24
9.25.
.9.26
9.27.
9.28.
9.29.
9.30.
9.31.
9.32.
9.33.
.9.34
.9.35
9.36.
.9.37

183 ................................................................................................INTRODUCTION
183 ................................................................................. GROUND RULES
- 185 ............................................................ PROJECT CHARTER
188 ............................................................................... SIPOC DIAGRAM
"" 190 ............................................................ RACI CHART
191 ................................................................. GANTT CHART
193 ............................................................... VOICE OF THE CUSTOMER
) 200 ..................................... QUALITY FUNCTION DEPLOYMENT( QFD
213 ................................................... METRICS DETERMINATION
216 .............................................................. CHECK SHEETS/LISTS
217 ..................................................................................... PARETO CHART
)( 220 ................................................. PRIORITIZATION MATRIX
229 ........................................... NOMINAL GROUP TECHNIQUE NGT
230 ............................................. BOX PLOT OR BOX AND WHISKER
236 ........................................... MULTI-VARI INTERVAL PLOT
240 .................................................................................... HISTOGRAM
245 .................................................... FLOW CHART OR PROCESS MAP
252 .................................. SPAGHETTI (WORKFLOW) DIAGRAMS
253 ........................................................... FOUR BLOCKS DIAGRAM
256 .................. VALUE-ADDED & NON V.A ANALYSIS
258 ........................................................BRAIN STORMING TECHNIQUE
260 ............................................................................. SIX HATS
262 ................. SITUATIONAL "SWOT" ANALYSIS
265 ............................................................................... AFFINITY DIAGRAM
"266 ................................................... VALUE STREAM MAPPING "VSM
270 ....................................................... CAUSE AND EFFECT DIAGRAM
275 .................................................................. SCATTER DIAGRAM
"280 ....................FAILURE MODE AND EFFECT ANALYSIS "FMEA
"284 .......................................... VISUAL CONTROL APPROACH "FIVE S
289 ........................................ KAIZEN IMPROVEMENT PRINCIPLE
" " 292 ....................................................... POKA YOKE
" " 293 ........................................................................... JUST IN TIME
294 .................................................................................... DASHBOARD
296 ....................................................................................BENCHMARKING
"298 .........................................DESIGN OF CONTROL "DOC
"299 ..................................................... TIME VALUE OF MONEY "TVM
303 ..................................... MEETINGS EFFECTIVE MANAGEMENT

321 ...........................................................................................
10. 321 .................................................
.10.1
.10.2
.10.3
10.4.
10.5.
.10.6
6

321 ................................................................................................INTRODUCTION
322 .....................................................................HISTORICAL TIP
322 ................................... USES OF STATISTICS IN BUSINESS
324 .............................................................. BRANCHES OF STATISTICS
325 .............................................................................. SOURCES OF DATA
326 ............................................................. NUMERICAL DATA TYPES

 6
.10.7
.10.8

332 ........................................... DATA COLLECTION TECHNIQUES

334 ........................................................................ STATISTICAL STUDY

337 ...................................................................................
11. 337 .........................................................................
.11.1
11.2.
.11.3

337 ................................................................................................INTRODUCTION
338 ......... DATA SUMMARY USING DESCRIPTIVE MEASURES
380 ......................... DATA PRESENTING USING GRAPHS

397 .....................................................................................
12. 397 .................................................................
.12.1
.12.2
12.3.
.12.4
12.5.

397 ................................................................................................INTRODUCTION
401 ................................................................... PROBABILITY DEFINITION
408 ........................ CONTINUOUS PROBABILITY DISTRIBUTIONS
440 .......................... SPECIAL CONTINUOUS PROBABILITY DISTRIBUTIONS
454 ................................. DISCRETE PROBABILITY DISTRIBUTION

481 .....................................................................................
13. 481 ...........................................................................
.13.1
13.2.
13.3.
13.4.
.13.5
13.6.
.13.7
13.8.
.13.9

481 ................................................................................................INTRODUCTION
481 .................................................... THE POPULATION ANDTHE SAMPLE
483 ...................................................NON PROBABILISTIC SAMPLING
484 ................................................................ PROBABILISTIC SAMPLING
491 ........................................................................... SAMPLE STATISTICS
492 .......................................................... SAMPLING ERRORS
493 ................................................. SAMPLING ERRORS CORRECTION
493 ...........................................................SAMPLE SIZE DETERMINATION
494 ................................................................ SAMPLE SIZE CONSTRAINTS

496 .....................................................................................
14. 496 ...............................................................................................
.14.1
.14.2
.14.3

496 ................................................................................................INTRODUCTION
496 ...................................................................................... POINT ESTIMATE
496 ............................................................................ INTERVAL ESTIMATION

509 ..................................................................................
15. 509 ..............................................................
.15.1 509 ................................................................................................INTRODUCTION
15.2. ?510 ................................................................WHAT IS REGRESSION
15.3. 510 .................................................................. TYPES OF REGRESSION
15.4. 511 ............................................................. USES OF REGRESSION
15.5. 512 ..... DIFFERENCE BETWEEN REGRESSION AND CORRELATION
.15.6 513 ....................................... BIVERATE DATA & CORRELATION
15.7. )515 ................................. COEFFICIENT OF LINEAR CORRELATION (R
15.8. 518 ...................................................... VARIANCE OF REGRESSION LINE
.15.9 519 .................................................................... COVARIANCE COEFFICIENT
.15.10 520 .......................................................... LEAST SQUARES LINES
6

525 ..................................................................................
16. 525 .......................................................................................
.16.1
16.2.
16.3.
16.4.

525 ................................................................................................INTRODUCTION
) (526 ................................................................ ANOVA STEPS
527 ............................................................ ASSUMPTIONS OF ANOVA
528 INTERPRETATION OF REGRESSION & ANOVA OUTPUTS

539 ....................................................................................
17. 539 ..................................................................................
.17.1
.17.2
.17.3

539 ................................................................................................INTRODUCTION
539 .......................................................................TYPES OF HYPOTHESES
540 ................................................ TEST OF HYPOTHESES CONCEPT

.17.4
.17.5
.17.6
.17.7
17.8.
.17.9
.17.10
.17.11
.17.12
.17.13

542 .......... LEVEL OF SIGNIFICANCE FOR HYPOTHESES

543 ........................... TEST OF HYPOTHESES ERROR TYPES
546 ................................................................................ POWER OF THE TEST
546 ............................................ TEST OF HYPOTHESES USAGES
546 ................................................ TYPES OF HYPOTHESES TESTS
547 ....................................REJECTION AREA DETERMINATION
549 ...................... ASSUMPTION FOR TESTING HYPOTHESES
550 .............................. TEST OF HYPOTHESES PROCEDURE
552 .................. TESTING HYPOTHESES WITH COMPUTER
553 ................................... EXAMPLES ON HYPOTHESES TESTING

564 ................................................................. REFERENCES

567 ..................................................................... RANDOM NUMBERS TABLE
568 ................................................................ RANDOM NUMBERS TABLE
569 ........................................................................................ NORMAL SCORES
571 .........................................................................................
576 .............................................................................
" " 577 ............................................. CRITICAL VALUES FOR T DISTRIBUTION
578 ................................ CRITICAL VALUES FOR
DISTRIBUTION
579 ............................................. CRITICAL VALUES FOR F DISTRIBUTION
580 ............................................. CRITICAL VALUES FOR F DISTRIBUTION

584 .................................................................... INDEX

Six Sigma

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Six Sigma



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6

Six Sigma


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:
.1 " : Six Sigma
"
Six Sigma

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6

Six Sigma

Six Sigma

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Six Sigma




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Six Sigma
.


Six Sigma



Improvement
6

Process Redesign .Process Re-Engineering
Variability

.

Statistical Process
" Control "SPC
Control Charts


Special and Common Causes .

Measurement System
Analysis MSA





Six Sigma.

.



Non-Normal Data Normal Data




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.2 " : Six Sigma "



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Six
Sigma
Data Analysis
Tools Ideas Treatment Techniques
6

10

Qualitative Approaches
.Quantitative Approaches
.3 " : "












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6

11

Descriptive Statistics
Estimation
Hypothesis Tests
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Validity and
Reliability

Inferential Statistics
Population Parameters

Population
X
.X

12

- -
.






.



Samples Populations


.

Estimation

Population Parameters Sample
Statistics
Point Estimate
.Interval Estimate
6

13

Correlation Linear Regression


Dependant Result
Effect Y
Independent Predictor Cause
X .

Regression
:


Analysis of Variables . ANOVA


Response Total Variation
Variation Within Groups
Variation Between Groups

F Ratio






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6

14

Test of Hypothesis



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2008

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202 22614720 / 012 7438220

15

.1
Six Sigma Meaning, Benifits, and Requirements
.1.1 Introduction
Six Sigma

:
.1

Define Measure
Analyze Improve
Control
DMAIC



.
.2 Six Sigma



Process control
Process design and Capability

.
6

16

.3 Six Sigma
Processes
) (

.
.4 Six Sigma

) Key Process Inputs Variables (KPIV's
) Key Process Outputs Variables (KPOV's

1-1
:

)Y = f ( x1 + x2 + x3 + ....... + xn
Voice of the Customer

KPOV's

)(Y

Noises Z's

/
Process/System

KPIV's

) (X

Variables Xs
)Y=F(X's

Voice of the Process

1-1 " Six sigma"

.5 Six Sigma

6

17

.
.6 Six Sigma
2-1
:
Low Delivery Time
.Cycle Time
Low Price .Cost
High Quality .Defects
Delivery

Customer

Cycle Time

Provider

Needs

Price

Cost

Do

Defects

Quality

2-1

" " Six

Sigma
.
.7 Six Sigma
)
( 3.4 .
.8 Six Sigma

6

18

Six Sigma .
Six Sigma

.

"

".
.1.2 Quality and its Pillars



.
:
-1 :Customer Satisfaction
Internal Customer

External Customer


.
6

19

-2 :Full Response



.
-3 :Measurement and Assessment


.

-4 :Regular Support



.
-5 :Continuous Improvement



.


.
.1.3 Six Sigma and Quality History

20

Craftsmen

/
.

Workshops
Factories "" Taylor





.

Fire Fighting


Fire Prevention





" " Shewart "
Statistical Process Control SPC
6

21

References

:
.1 ) (1989 .
.2 ) (1993
.
.3 ) (2004 .
.4 ) (2001 2
.
.5 ) (1989
.
.6 ) (2004
.
.7 ) (2001
.
.8 ) (1996

564

:
1. Alan H. Kvanli, Robert J. Pavur, Introduction to Bussiness
Statitics,1996, West publishing company.
2. Charles E. Ebeling, An introduction to reliabilityand
mainteanbaility engineeting, seventh edition 2007, M cGraw-Hill
publishing Company Limitted.
3. Deborah Rumsey , Statistics For Dummies, 2003, John Wiley &
Sons
4. Douglas C. Montgomery, Introduction to Statistical Quality
Control, Fourth edition 2007, John Willy & sons publishing Inc.
5. George Eckes, Six Sigma For Everyone, 2003, John Wiley & Sons
Inc
6. George Eckes, Six sigma team dynamics: the elusive key to
project success, 2003, John Wiley & Sons, Inc.
7. How To Measure Performance a Hanbook of Techniques and
Tools, ,1995, The Training Resources and Data Exchange
(TRADE)
8. Hubert K. Rampersad, total quality management, 2001, springerpublishing Inc.
9. John S. Oakland, Statistical Process Control, Fifth edition 2003.
10. Keki R. Bhote, the Power of Ultimate Six Sigma,2003, American
Management Association
11. Kenneth L. Arnold & Michael Holler, Quality Assurance Methods
and Technologies, 1976, McGraw-Hill publishing Company
Limitted.
12. Matt Barney & Tom McCarty, A Leader's Guide to Achieving
Rapid Business Improvement and Sustainable Results, 2002,
Prentice Hall PTR
13. Michael C. Thomsett, Getting Started in Six Sigma, 2005, John
Wiley & Sons, Inc.
14. Michael L. George, Lean Six Sigma for Service: How to Use Lean
Speed and Six Sigma Quality to Improve Services and
Transactions, 2003, McGraw-Hill publishing Company Limitted.
15. Michael L. George, The Lean Six Sigma Pocket Toolbook, 2005,
McGraw-Hill publishing Company Limitted.
16. Neil A. Weiss, Introductory statistics, seventh edition 2002,.
6

565

17. Paul Keller, six sigma demystified, 2005, McGraw-Hill publishing

Company Limitted.
18. Peter S. Pande & Robert P. Neuman, The Six Sigma Way, 2000,
McGraw-Hill publishing Company Limitted.
19. Praveen Gupta, Six Sigma Business Scorecard, 2003, McGrawHill publishing Company Limitted.
20. Stephen A. Zinkgraf, Six Sigma: The First 90 Days, 2006,
Prentice Hall PTR
21. Subir Chowdhury, Design for Six Sigma, 2003, Prentice Hall
PTR.
22. Thomas Pyzdek, 2003, The Six Sigma Project Planner, McGrawHill publishing Company Limitted
23. Thomas Pyzdek, The six sigma Handbook, 2003, McGraw-Hill
publishing Company Limitted.
24. W. Grant Ireson, Richard Y. Moss, Handbook of relaiability
engineering and management, 1995, McGraw-Hill publishing
Company Limitted.
25. Warren Brussee, Statistics for Six Sigma Made Easy, 2004,
McGraw-Hill publishing Company Limitted.
26. Alan H. Kvanli, Introduction to business statistics,1996, West
publishing company.

566