Lean Six Sigma

05 December 2016 02:52

What is Lean Six Sigma?

- A commitment to customers to offer the highest quality products at reduced cost
- A practical application of statistical tools to help measure, analyse, improve and control processes
- A benchmark for product and process capability on a quality basis
- A metric that demonstrates quality levels at 99.99967 percent performance for processes
DMAIC for Existing Processes
DMADV for New Processes

DMAIC
1. Define
Selection of Performance Characteristics critical in meeting customer requirements
What are the customer expectations of the process?
i. Determine the Project CTQs: gather verbatim VOC, prioritize VOC, translate to CTQs
ii. Define the Project:
iii. Project Charter: Business case; Problem & Goal statement; Project Scope; Milestones; Roles & Resp
iv. Map the Process: Process Operational Definition; Mapping Guidelines;
2. Measure
Creation and validation of a measurement system
What is the frequency of defects?
i. Select Project Y: Measures; CTQ prioritization; Types of Data; Fishbone diagram
ii. Develop Data Collection Plan: Establish Plan; Est. Operational Definitions; Sampling Procedures
iii. Variation: display & describe Variation; Causes of Variation; Run Chart; Bar Chart; Normal Curve
Total/Apparent Variation = Process Variation + Measurement Variation

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3. Analyse
Identification of sources of variation from performance objectives
Why, when and where do defects occur?
i. Process Capability: Base lining/Defects Per Million Opportunity/Calculate Current Sigma/Cp/Cpk
ii. Identify Possible Causes: Segmentation & stratification; Sub-Process mapping; Map analysis
iii. Narrow to Root Causes: Hypothesis testing; t-test; Chi-square test; Regression Analysis
iv. Quantify the Opportunity: Benefits from fixing root causes
Calculating Sigma of a Process:
No. of units processed/Sample size observed (N)
No. of Defects observed (D)
No. of Opportunities of defect per unit (O)
Defects Per Opportunity = D/(N*O)
Defects Per Million Opportunities = 1,000,000 * D/(N*O)
Look up for the Sigma Value in the Sigma Table
Yield (Goodness of Process O/P) = 1 - Percentage Defective Cp < 1 :: Process Variation exceeds
Process Capability: Specification Limits. Process is producing

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 Defects Per Opportunity = D/(N*O)
Defects Per Million Opportunities = 1,000,000 * D/(N*O)
Look up for the Sigma Value in the Sigma Table
Yield (Goodness of Process O/P) = 1 - Percentage Defective Cp < 1 :: Process Variation exceeds
Process Capability: Specification Limits. Process is producing
Helps us determine if a process, given its natural variance is capable of meeting customer requirements defects
Cp: Process Capability
USL: Upper Specification Limit
LSL: Lower Specification Limit
s: Expected standard deviation
Cp = (USL - LSL)/6s
Process capability looks at the spread of variation and does not look at how well the process is centred around
target value

Process Capability in Terms of Centricity:

Cpl = (Mean - LSL)/3s Cpu = (USL - Mean)/3s
Cpk = Min(Cpl, Cpu)
Target: Cp > 1 & Cpk = 1
4. Improve
Discovery of process relationships and establishment of new procedures
How can we fix the process?
i. Generate/Select Solutions: Brainstorming; Criteria Matrix; Idea screening
ii. Refine Solution: Error proofing
iii. Test Solution: Pilot planning; Verification of results
iv. Justify Solution: Cost Benefit analysis
5. Control
Control of implemented improvements to maintain gains and help ensure corrective actions are taken when
necessary
How can we make the process stay fixed?
i. Process Control Plan: Process Management Chart; Process Documentation; Control Chart; Response Plan
ii. Implement Solution: Stakeholder analysis; Implementation Elements
iii. Close Project: Documentation; Communication of Learning; Project Closure

Kano Model for Prioritizing CTQs

DMADV
1. Define: Initiate, Scope & Plan the project
2. Measure: Understand Customer needs and specify the CTQs
3. Analyse: Develop design concepts and high-level design
4. Design: Develop detailed design and control/test plan
5. Verify: Test design and implement full scale process

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