(Six Sigma Process):

TQM 1

/

5
1) (Define) (Deployment Phase)
2) (Measurement)
3) (Analysis)
4) (Improvement)
5) (Controlling Process)

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1 : (Define:D)

(Sigma)

3 (Champion) (Black Belt)
(Green Belt)

(Champion)

(Leader)
(Project)
(Measure) 1
2
1 1

2 1 (Six Sigma)

(Black Belt)
(Black Belt)



(Project)
(Cross-functional team members) (Project)
(Full-time project leader) 1 50
1 100
2
1 1 (Project)
2 3 ( Project )
( Project )

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( Green Belt )


( Project )
( Green Belt )
( Project )
( Part - time project ) 1 20
2
1 5
2 1
( Project )


2 : (Measurement:M)

3 : (Analysis:A)



4 : (Improvement:I) ( Design
of Experiments : DOE)

5 : (Controlling process:C)

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(Normal Distribution)

( Normal Distribution )
0 1(X ~ N(0,1))
100% X 6.1

....(6.1)

5 . 5 Z
6.1 Z

1.000
0.9973 1 - 0.9973 = 0.00270
0.00270 2 = 0.00135 Z
3 99.73% 3 6.2
3

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0.00135

0.00135

-3.0
2

1 0.9973

+3.02

6.2
5 . 5
Z
Z = 3

/
/
99.73 / 0.27
Z = 6
/ /
99.9999998
Z = 3 Z = 6 ( Harry 1978 ) 6.1
6.1

Z = 3 3
- 20,000
- 15
- 5,000
-
2
- 200,000
- 7

Z = 6 6
- 7
- 1 7
- 1.7

-
1 5
- 68
1 34

6.1 Z = 6
Z = 3

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LSL

USL

0.00000000098
7

0.00000000098
7

6 5 4 3 2 2 3 4 5 6

6.3 Z = 1 Z = 6
6.3 Z
(Defect) (Part per million : ppm)
(Sigma: )
6.2
6.2

( Spec. Limit)

(%)

(part per million : ppm)

68.27

317300

95.45

45500

99.73

2700

99.9937

63

99.999943

0.57

99.9999998

0.002

6.3 6.2 Z
/

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/
() 6.4 6.3
(Normal distribution)
Shifted 1.5
-1.5 +1.5

LSL

USL

6 5 4 3 2 2 3 4 5 6

6.4

1.5
6.3
6.3 (defect)
()

( Spec. Limit)

(%)

30.23
69.13
93.32
99.3790
99.97670
99.999660

(ppm.)
697700
308700
66810
6210
233
3.4

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6.3 ()
6
3.4 ( 3.4 parts per million: ppm)
66,810
( 66,810 parts per million: ppm)

6.5
6.5 3
10
4 30
5 5
70
6

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( Y Key Process Output Variable : KPOV)
(Dependent)

( KPIV )

Y =
( KPOV )

Y (KPOV)
(Dependent)
(Output)
(Effect)
(Symptom)
(Monitor)

F (X)
KPIV : Key Process Input Variable
KPOV : Key Process Output Variable

X1,X2,,Xn(KPIV)
(Independent)
(Input)
(Cause)
(Problem)
(Control)

X X

( Key Process Input Variable : KPIV )
6.1
(Hard Disk Drive)

( Hole Bushing )
5

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(Hard Disk Drive)

(SWG hole bushing )

6.6 (Hard Disk Drive)

1 (Define) :

(Problem Statement )
(Project Objective)

1. 1.
(Silicate bush)
2.
2. 3.
( 4.
)
(Design of Experimental:DOE) 7
3.
(7QCTools)
(Porprotion Test) ( ttest)(F-test)

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(Goal of Production)
1. 30 %( 2,000,000
1,700,000
2. ( 200 PCs
251 PCs )

(Project Period)
-

2 (Measurement) :
(burr) 3

200 pcs

210 pcs

220 pcs

230 pcs

260 pcs

250 pcs
(Burr)

240 pcs

(Burr)

(Burr)
6.7 (Burr)

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3 (Analysis) : KPIV (Key Process Input

Variable) KPOV(Key Process Output Variable)
KPIV (Key Process Input Variable) (Silicate
brush feature: X1) (Operator: X2)
(Tool life of main machine : X3) (Part
condition: X4)
(Tooling condition: X5)
KPOV (Key Process Output Variable)
(Swage hole burr condition)
(Swage hole scratch)




6.8

(Method)

(Machine)

(Run out)

( Man)

(Material)

6.8

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4 (Improvement) :


(Rework)
(Analysis of variance)

5 (Controlling Process) :
1 4

(Process)

6.1

(Process Capability Index) (Process Cycle Time)
/(Defects per Opportunity-DPO /
Defects per Million Opportunities-DPMO) /( Yield / Rolled
Though out Yield-RTY)

5
(Process Cycle Time)

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1
1
(Defects per Opportunity-DPO)

3

500 3
5
DPO 1.0 %

(Defects per
Opportunity-DPO / Defects per Million Opportunities-DPMO) DPMO
// ()


DPO DPMO
4
1

1 = 1 Unit
1 = 1 Opportunity
1 = 4

O (Opportunities for a defect)

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D (Defect) /
U (Unit)
DPU (Defect per Unit)
D
(6.2)
DPU
U

DPO

.(6.3)

DPU
D

O
UO

.(6.4)

DPMO DPO 10 6

(Defect) DPU DPO

D
DPU 1
U

DPO

DPU 1
0 .25
O
4

D
DPU 2
U

DPO

DPU 2
0 .50
O
4

6.2
6 A B C D E F
(Defect) (Unit)
(opportunity per unit)
6.4 D U O DPU DPO DPMO

DPU

DPO

DPMO

A (Type A)
B (Type B)
C (Type C)
D (Type D)
E (Type E)
F (Type F)

21
10
8
68
74
20

327
350
37
743
80
928

92
85
43
50
60
28

0.064
0.029
0.216
0.092
0.925
0.022

0.0007
0.0003
0.0050
0.0018
0.0154
0.0008

698
336
5,028
1,830
15,417
770

0.0016

1,554

Total

201

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(DPU)
(DPO)
1,000,000 (DPMO) A
21
D
A:
0.064
DPU

U
327
DPU
0.064
0.0007
DPO

O
92

DPMO DPO 10 6 0.0007 10 6 698

1,000,000 (DPMO) X
Y
1,000,000 (DPMO)
P a r e to C h a r t o f ty p e
25000

100
80

15000

60

10000

40

5000

20

0
ty p e
Count
Pe rce nt
Cum %

T ype E
15417
6 4 .0
6 4 .0

T ype C
5028
2 0 .9
8 4 .9

T ype D
1830
7 .6
9 2 .5

T ype F
770
3 .2
9 5 .7

O th e r
1034
4 .3
1 0 0 .0

Pe r c e n t

DPM O

20000

6.6

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Input
Output


(Poisson Distribution)

x 0

e x
e
x

e D/U e DPU

Y (Throughput Yield)
X
(Poisson)

TP ( Throughput yield)

TP e DPU

RT (Rolled Throughput yield)

1 m m
RT

i 1

TPi

; i= 1,2,,m

2 (First - time yield)
(Final Yield) (First - time yield)
(rework)
(First - time yield)

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(Throughput yield)
(Rolled throughput yield) (rework)

6.3 5 467
(Unit) (DPU) 0.01071 (5/467)

x 0 e DPU

e 0.01071
0 . 98935

6.4 5
(Input)
(rework) (Scrap)

6.5

(Input)
1
2
3
4
5

1,000
960
874
804
732

(rework)

920
754
633
519
493

40
120
171
213
221
765

Throughput

(Scrap)
Yield

40
86
70
72
18
286

960
874
804
732
714

0.92
0.82
0.84
0.82
0.95
RT

=0.4936

6.5
6.7 1 1,000
920 40 40

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1 960
(Throughput yield : TP ) 0.92 (920/1,000 = 0.92)
1,000
Y1 = 0.92

Rework ( 4%)

960

Y2 = 0.82

Scrap ( 9%)
Rework ( 9%)

754
Y3 = 0.84

Scrap ( 8%)
Rework ( 8%)

633

Y4 = 0.82

Scrap ( 9%)
Rework ( 9%)

519

Y5 = 0.95
493

Scrap ( 4%)

Scrap ( 2.5%)
Rework ( 2.5%)

40
960
86
874
70
804
72
732
18
714

YI Throughput Yield

6.7 5
2 960
754 120 86
2 874
(Throughput yield : TP ) 0.82 ( 724 / 920 = 0.82 )
3 874
633 171 70

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3 804
(Throughput yield : TP ) 0.84 ( 633 / 754 = 0.84 )
4 804
519 213 72
4 732
(Throughput yield : TP ) 0.82 ( 519 / 633 = 0.82 )
5 732
493 221 18
5 714
(Throughput yield : TP ) 0.95 ( 493 / 519 = 0.95 )
(First - time
yield) (Throughput yield)
960
1 (First - time yield)
=
0.96
1000
920
(Throughpout yield) =
0.92
1000
(First - time yield) 1
0.96 100 96
1 (Throughput yield)
0.92 100 92

874
0.91
960
754
(Throughput yield) = 0.82
920
(First - time yield) 2
0.91 100 91
2 (Throughput yield)
0.82 100 82
2

(First - time yield)

(First - time
yield)

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(Rework)
(Throughput yield)

(Rework)

(Rolled Throughput yield)
(Rework)
714
Final Yield
=
0.714
1000
Rolled throughput yield:

RT

= TPi
i1

= (0.92 0.82 0.84 0.82 0.95)

= 0.4936
Final yield 0.714 100
72 ()
(Rolled throughput yield) 0.4936 100
( Rework ) 50

6.5 10 (step)
(throughput yield)
Y1 = 0.92

Y2 = 0.82

Y3 = 0.95

Y4 = 0.82

Y5 = 0.93

Y6 = 0.93

Y7 = 0.92

Y8 = 0.91

Y9 = 0.83

Y10 = 0.85

6.8 10
(Rolled throughput yield)
RT

m
TPi
i 1

= ( 0.92 0.82 0.85 ) = 0.27

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100 27
6.6 10

(Defect)

(Unit)

DPU = D/U

Rolled throughput yield

1
2
3
4
5
6
7
8
9
10

5
75
18
72
6
28
82
70
35
88

1495
1420
1402
1330
1324
1296
1214
1144
1109
1021

0.00334
0.05282
0.01284
0.05414
0.00453
0.02160
0.06755
0.06119
0.03156
0.08619

0.99666
0.94855
0.98724
0.94730
0.99548
0.97863
0.93469
0.94065
0.96893
0.91742

497

RT =

0.67317

(Rolled throughput
yield)
RT

= TP
i 1

= 0.99049 0.91564 .. 0.929

= 0.67317
100 67

(Sigma)
(Schmidt and Launsby (1997) ) (Sigma quality level)

= 0.8406 29.37 2.221 ln ppm

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6.6 800
142
(Sigma)
142
D
DPU =
0.1775

U
800

0.177510 = 177,500 ppm

0.8406 29.37 2.221 ln ppm

0.8406 29.37 2.221 ln177,500

2.43

2.43 (Sigma)

1.5

Z DPU 0.1775

1 0.1775 = 0.8225 Z = 0.9256

= Z + 1.5
= 0.9256 + 1.5
= 2.4256

2.4256 2.43

7

(Improvement and
Development) (Design of Experiments :DOE)
(Measurement System Analysis :MSA)

4 (S4)

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1.
2.
3.
4.

(4 Sigma)
(6 Sigma)

1. (6 ) (Six
Sigma)
2. (Six Sigma)
3.
0.001
(Sigma)
4. (Six Sigma)