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Six Sigma
Six Sigma
Jayesh Bendale -64 Prerna Kadam -75 Keval Mhatre -86 Mangesh Pandure -89 Kiran Phapale -92 Ketan Rane -96 Amol Shitole -112 Preeti Singh -113 Meera Upadhyay -120
Contents
Introduction Concept of Six Sigma DMAIC PDCA SIPOC Four Levels in Six Sigma Advantages
Six Sigma
It is a Process To achieve this level of performance you need to: Define, Measure, Analyse, Improve and Control
It is a Philosophy Anything less than ideal is an opportunity for improvement Defects costs money Understanding processes and improving them is the most efficient way to It is Statistics achieve lasting results 6 Sigma processes will produce less than 3.4 defects per million opportunities
0 00 0 0, 0 0 00 0 0, 0 0 00 0 0, 0 0 00 0 0, 0 0 00 0 0, 0 0 00 0 0, 0 0 00 .
00 .
00 . # of Sigmas
00 .
00 .
FMEA..
Step
Start KANBAN Card Shop Order Heat Treatment Hardness Testing Operation Layout Tooling and Gauges Grinding / Honing Fitting / Polishing Inspection End
OK? Yes
Sigma Curve
DMAIC simplified
Define What is important? Measure How are we doing? Analyze What is wrong? Improve Fix whats wrong Control Ensure gains are maintained to guarantee performance
DMAIC approach
D Define
Validate the practical problem by collecting data Convert the practical problem to a statistical one, define statistical goal and identify potential statistical solution Confirm and test the statistical solution
A C T
N A L P
I N V E ST I G A T E C O R R E C T & S T A N D A R D I SE
R E V I E W F E E D B A C K & M A K E C O R R E C T I O N S S T A N D A R D I S E C H E C K , A C T D O , C L A R I F Y I D E N T I F Y
O B JE C T I V E S P O S S I B L E B E S T
C A U S E S
B E N C H M A R K I D E N T I F Y
P R A C T I C E
T E A M
R O L E S F I X
I M P L E M E N T
Q U I C K
E V A L U A T E
&
V A L I D A T E
E N L I G H T E N & I M P L E M E N T
C A R R Y O U T T R IA LS PR O V E C A U SE S A N A L Y SE D A T A T O U N D E R ST A N D H O W PR O B L EM O C C U R S ID E N T I FY P O SSIB L E SO L U T I O N S T O
P IL O T S T U D Y S O L U T IO N T O V E R IF Y D A T A C O U N T E R M E A S U R E T R A IN IN G
C O M
U N IC A T IO N
PDCA was created by W Edwards Deming in the 1950s as an easy to follow Problem Solving Cycle. Deming was tasked with helping Japan rebuild its economy in the 1950s. His purpose was to use PDCA with a Continuous Improvement process to help rebuild Japanese industries so that they could compete in the world market in the future.
D O
K C E H C
PDCA Cycle
SIPOC
6 Training
Master Black Belt
Mentor, trainer, and coach of Black Belts and others in the organization.
Delivers successful focused projects using the six sigma methodology and tools.
Green Belts
Participates on and supports the project teams, typically in the context of his or her existing responsibilities.
Black Belt
Black Belt
Backbone of Six Sigma Org Mentor Green Belts Full time resource Deployed to complex or high risk projects
Green Belt
- Part time or full time resource - Deployed to less complex projects in areas of functional expertise
TreMyn 2004
$ 16 billion (*since inception in 1980s) Johnson & Johnson $500 million Honeywell $600 million
24
Six Sigma Savings as % of revenue vary from 1.2 to 4.5 % For $ 30 million/yr sales Savings potential $ 360,000 to $ 1.35 million. Investment: salary of in house experts, training, process redesign.