Six Sigma (6σ) is a set of techniques and tools for process improvement.
It was introduced by
American engineer Bill Smith while working at Motorola in 1986
A six sigma process is one in which 99.99966% of all opportunities to produce some feature of a
part are statistically expected to be free of defects.
Six Sigma strategies seek to improve the quality of the output of a process by identifying and
removing the causes of defects and minimizing impact variability in manufacturing and business
processes
Six sigma is a statistical measure of variation. The full six sigma equals 99.9997%
accuracy. Six sigma is a
methodology for improving key processes. Six sigma is a “tool box” of quality and
management tools for problem
resolution. a business philosophy focusing on continuous improvement.
Six Sigma Symbol
The term "six sigma" comes from statistics and is used in statistical quality control, which
evaluates process capability.
Processes that operate with "six sigma quality" over the short term are assumed to produce long-
term defect levels below 3.4 defects per million opportunities (DPMO)
Statistical view of
6sigma
Features of Six Sigma: It has the following important features:
1. Six sigma shifts the paradigm quality as the cause of good business performance and not the
effect. Before 1980’s all process and product improvement techniques were aimed at continuous
improvement of quality. Six Sigma propagates that all-round quality performance(error free
performance excellence with continuous improvement) is bound to result in the attainment of the
desired business excellence in terms of reduction in the cost of production, Maximizing of
customer satisfaction and return on Investment. \
2. The philosophy of Six Sigma is to make fewer mistakes in all the organizational activities and
keep on reducing the mistakes.
3. It is a business strategy to reduce the cost by attaining good quality.
4. It is a statistical process control technique aimed at achieving total confidence in the
company’s products and service performances for the customers as well as the management.
5. It is a philosophy of achieving the ultimate goal of ‘Do it right the first time every time’.
6. It is a performance measure. The sigma and Part Per Million(ppm) are correlated as indicated
under;
****Six Sigma projects follow two project methodologies inspired by Deming's Plan–Do–Study–Act Cycle.
These methodologies, composed of five phases each, bear the acronyms DMAIC and DMADV
DMAIC is used for projects aimed at improving an existing business process.
DMADV is used for projects aimed at creating new product or process designs Methodologies of 6 sigma
ACCEPTANCE SAMPLING- (A FORM OF INSPECTION)
Acceptance sampling is an important field of statistical quality control that was
popularized by Dodge and Romig and originally applied by the U.S. military to the
testing of bullets during World War II. If every bullet was tested in advance, no
bullets would be left to ship. If, on the other hand, none were tested, malfunctions
might occur in the field of battle, with potentially disastrous results.
Dodge reasoned that a sample should be picked at random from the lot, and on the
basis of information that was yielded by the sample, a decision should be made
regarding the disposition of the lot. In general, the decision is either to accept or
reject the lot. This process is called Lot Acceptance Sampling or just Acceptance
Sampling.
Acceptance sampling is "the middle of the road" approach between no inspection
and 100% inspection. There are two major classifications of acceptance plans:
by attributes ("go, no-go") and by variables. The attribute case is the most common
for acceptance sampling, and will be assumed for the rest of this section.
A point to remember is that the main purpose of acceptance sampling is to decide
whether or not the lot is likely to be acceptable, not to estimate the quality of the
lot.
NOTE:an attribute is a characteristic of an object, A variable is a logical set of attributes.[1] Variables can "vary" - for example, be high or low.
attribute could be just the word "low"
TYPES OF ACCEPTANCE PLANNING:
Single sampling plans: One sample of items is selected at random from a lot
and the disposition of the lot is determined from the resulting information.
These plans are usually denoted as (n,c) plans for a sample size n, where the lot
is rejected if there are more than c defectives. These are the most common (and
easiest) plans to use although not the most efficient in terms of average number
of samples needed.
Double sampling plans: After the first sample is tested, there are three
possibilities:
1. Accept the lot
2. Reject the lot
3. No decision
If the outcome is (3), and a second sample is taken, the procedure is to combine
the results of both samples and make a final decision based on that information.
Multiple sampling plans: This is an extension of the double sampling plans
where more than two samples are needed to reach a conclusion. The advantage
of multiple sampling is smaller sample sizes.
Acceptance Sampling
The goal in any production operation is to eliminate defects. However, as hard as we try to remove them,
defects will happen. Since we know defects will occur, one of the questions we need to ask is: How much error
can we accept? We know that even the best batter is going to strike out. What is the acceptable strikeout rate
for a given batter? In order to evaluate our production lots or batches, we need to come up with a
plan. Acceptance sampling is a means to evaluate lots to see if they pass the standard.
Acceptable Quality Level (AQL)
Since we know that defects are unavoidable, we need to accept that certain batches or lots are going to have them.
Buyers can accept a certain level of off-color paint or scuffed edges. The overall percentage is usually somewhere
between 0.1 and 2%. This is the acceptable quality level (AQL). This number varies by product and defect. For a window
manufacturer, discolored sills may have an AQL of 1.8%. Discolored glass, on the other hand, may have an AQL of 2% (or
even higher). We'll see this number play into our diagram a little later.
The AQL is a percent defective that is the base line requirement for the quality of the
producer's product. The producer would like to design a sampling plan such that
there is a high probability of accepting a lot that has a defect level less than or equal
to the AQL.
Lot Tolerance Percent Defective (LTPD): The LTPD is a designated high defect level
that would be unacceptable to the consumer. The consumer would like the sampling
plan to have a low probability of accepting a lot with a defect level as high as the
LTPD.
Type I Error (Producer's Risk): This is the probability, for a given (n,c) sampling plan,
of rejecting a lot that has a defect level equal to the AQL. The producer suffers when
this occurs, because a lot with acceptable quality was rejected. The symbol α is
commonly used for the Type I error and typical values for α range from 0.2 to 0.01.
Type II Error (Consumer's Risk): This is the probability, for a given (n,c) sampling plan,
of accepting a lot with a defect level equal to the LTPD. The consumer suffers when
this occurs, because a lot with unacceptable quality was accepted. The symbol β is
commonly used for the Type II error and typical values range from 0.2 to 0.01.
Operating Characteristic (OC) Curve: This curve plots the probability of accepting
the lot (Y-axis) versus the lot fraction or percent defectives (X-axis). The OC curve is
the primary tool for displaying and investigating the properties of a LASP.
Average Outgoing Quality (AOQ): A common procedure, when sampling and testing
is non-destructive, is to 100 % inspect rejected lots and replace all defectives with
good units. In this case, all rejected lots are made perfect and the only defects left are
those in lots that were accepted. AOQs refer to the long term defect level for this
combined LASP and 100 % inspection of rejected lots process. If all lots come in with
a defect level of exactly p, and the OC curve for the chosen (n,c) LASP indicates a
probability pa of accepting such a lot, over the long run the AOQ can easily be shown
to be:
AOQ=pap(N−n)/N
where N is the lot size.
Average Outgoing Quality Level (AOQL): A plot of the AOQ (Y-axis) versus
the incoming lot p (X-axis) will start at 0 for p=0, and return to 0 for p=1 (where
every lot is 100 % inspected and rectified). In between, it will rise to a
maximum. This maximum, which is the worst possible long term AOQ, is
called the AOQL.
Average Total Inspection (ATI): When rejected lots are 100 % inspected, it is
easy to calculate the ATI if lots come consistently with a defect level of p. For a
LASP (n,c) with a probability pa of accepting a lot with defect level p, we have
ATI=n+(1−pa)(N−n),
Average Sample Number (ASN): For a single sampling LASP (n,c) we know each and
every lot has a sample of size n can be calculated assuming all lots come in with a
defect level of p. A plot of the ASN, versus the incoming defect level p, describes the
sampling efficiency of a given LASP scheme.
Making a final choice between single or multiple sampling plans that have acceptable
properties is a matter of deciding whether the average sampling savings gained by
the various multiple sampling plans justifies the additional complexity of these plans
and the uncertainty of not knowing how much sampling and inspection will be done
on a day-by-day basis.
