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ISSN: 2248-9622, Vol. 7, Issue 1, (Part -5) January 2017, pp.49-52
ABSTRACT: This paper discusses the Methods of Six Sig ma and its applicat ions used in project management.
Keywords: Six Sig ma, Pro ject Management, Standard Dev iation, 3.4 defects, DMAIC, ANOVA.
I. INTRODUCTION
Six Sigma is basically the application of
Statistical formulas and Methods to eliminate defects,
variation in a product or a process. For example if you
want to find the average height of male population in
India, you cannot bring the entire population of more
than 2 billion into one room and measure their height
for a scenario like this we take samples that is we pick
up sample(people) from each state and use statistical
formulas to draw the inference about the average
height of male population in a population which is
more than 2 billion. One more example would be say
a company manufactures pistons use d in motor cycles
the customer demand is that the piston should not a
diameter more than 9 cm and less than 5 cm anything Six Sig ma is Denoted by the Greek alphabet σ which
manufactured outside this limits is said to be a is shown in the table above and is called as Standard
variation and the six sigma consultant should confirm deviation. The father of Six Sig ma is Bill Smith who
that the pistons are manufactured within the said limits coined the term Six Sigma and implemented it in
else if there is variation in the range then the company Motorola in the 1980’s.
is not operating at 6 sigma level it is operating at a Six Sigma is implemented in Fi ve Phases which are
very low level. Define, Measure, Analyze, Improve, Control and
A company is operating at six sigma level we will discuss each phases in brief and the various
implies that there are only 3.4 defects per million methods used in Six Sigma.
opportunities for example an airline company Define
operating at six sigma level means that it loses only 3.4
baggage’s per million of the passenger it handles. The objecti ves within the Define Phase which is
first phase in DMAIC framework of Six Sigma
Below is Shown the Six Sigma Table and a graph are: -
explaining the meaning of various levels of Six Sigma. Define the Project Charter
Sigma Level Defect Rate Yield Define scope, objectives, and schedule
Percentage Define the Process (top-level) and its stake
2σ 308,770 dpmo (Defects Per 69.10000 % holders
Million Opportunities)
3σ 66,811 dpmo 93.330000 % Select team members
4σ 6,210 dpmo 99.38000 % Obtain Authorization fro m Sponsor
5σ 233 dpmo 99.97700 % Assemble and train the team.
6σ 3.44 dpmo 99.99966 % Project charters the charter documents the why,
how, who and when of a project include the
following elements
Problem Statement
Project objective or purpose, including the
business need addressed
Scope
Deliverables
Sponsor and stakeholder groups
Team members
Project schedule (using GANTT or PERT as Measure Phase: In the Measure phase, we collect all
an attachment) the data as per the relationship to the voice of customer
Other resources required and relevantly analyze using statistical formulas as
given in the above table. Capability analyses is done in
Work break down Structure measure phase.
It is a process for defining the final and
intermediate products of a project and their The process capability is calculated using the
relationship. Defining Project task is typically formula CP = US L-LS L/6 * Standard Devi ation
complex and accomplished by a series of where CP = process capability index, US L =
decomposition followed by a series of aggregations Upper S pecificati on Li mit and LSL = Lower
it is also called top down approach and can be used Specification Limi t.
in the Define phase of Six Sig ma framewo rk. The Process capability measures indicates the
following
Now we will get into the formulas of Six Sigma 1. Process is fully capable
which is shown in the table below. 2. Process could fail at any time
Central tendency is defi ned as the tendency for 3. Process is not capable.
the values of a random variab le to cluster round its When the process is spread well within the
mean, mode, or median. customer specification the process is considered to
Central Tendency Population Sample be fully capable that means the CP is more than
Mean/Average µ =∑ (Xi)^2/N XBar=∑ 2.In this case, the process standard deviation is so
(Xi)^2/n
small that 6 times of the standard deviation with
Median Middle value of Data
Mode Most occurring value in the data reference to the means is within the customer
Dispersion specification.
Variance σ ^2 = ∑(X- S^2 = ∑(Xi-
µ)^2/ N XBar)^2/ n-1 Example: The S pecified li mits for the di ameter
Standard Deviation σ= √ ∑(Xi- µ)^2/ S = √ ∑(Xi- of car tires are 15.6 for the upper limit and 15
N XBar)^2/ n-1
Range Max-Min
for the lower limit wi th a process mean of 15.3
and a standard devi ati on of 0.09. FindCp and Cr
Where mean is the average for example if what can we say about Process Capabilities?
you have taken 10 sample of pistons randomly from Cp= USL-LSL/ 6 * Standard deviation = 15.6 – 15
/ 6 * 0.09 = 0.6/ 0.54 = 1.111
the factory and measured their diameter the average
would be sum of the diameter of the 10 pistons Cp= 1.111
divided by 10 where 10 the number of observations the Cr = 1/ 1.111 = 0.9
Since Cp is greater than 1 and therefore Cr is less
sum in statistics is denoted by ∑. In the above table X,
Xi are the measures of the diameter of the piston and than 1; we can conclude that the process is
µ,X-Bar is the average. potentially capable.
Mode is the most frequently observed
measurement in the diameter of the piston that is if 2 Analyze Phase:
pistons out 10 samples collected have the diameter as In this Phase, we analyze all the data collected in the
measure phase and find the cause of variation. Analyze
6.3 & 6.3 then this is the mode of the sample and
median is the midpoint of the observations of the phase use various tests like parametric tests where the
diameter of the piston when arranged in sorted order. mean and standard deviation of the sample is known
and Nonparametric Tests where the data is categorical
From the example of the piston we find that
the formulas of mean, median, mode does not correctly for example as Excellent, Good, bad etc.
depict variation in the diameter of the piston
Parametric Hypothesis Test -A hypothesis is a
manufactured by the factory but standard deviation
formula helps us to find the variance in the diameter of value judgment made about a circumstance, a
the piston manufactured which is varying from the statement made about a population. Based on
experience an engineer can for instance assume that
customer mentioned upper specification limit and
lower specification limit. the amount of carbon monoxide emitted by a
The most important equation of Six Sigma is certain engine is twice the maximu m allowed
legally. However, his assertions can only be
Y = f(x) where Y is the effect and x are the causes so if
you remove the causes you remove the effect of the ascertained by conducting a test to compare the
defect. For example, headache is the effect and the carbon mono xide generated by the engine with the
legal requirements.
causes are stress, eye strain, fever if you remove this
causes automatically the headache is removed this is If the data used to make the comparison are
implemented in Six Sig ma by using the Fishbone or parametric data that is data that can be used to
derive the mean and the standard deviation, the
Ishikawa diagram invented by Dr Kaoru Ishikawa.
Control Phase: In the Control phase we document all systematically against this problem statement which is
the activities done in all the previous phases and using further analyzed in Analyze phase by performing
control charts we monitor and control the phase just to various hypothesis tests and process optimization in
check that our process doesn’t go out of control. Improve phase by removing the junk factors that is in
Control Charts are tools used in Minitab Software to the equation y = f(x1, x2,x3…….) we remove the
keep a check on the variation. All the documentation causes x1, x2 etc. by the method of Design of
are kept and archived in a safe place for future Experiments and factorial methods. Finally we can
reference. sustain and maintain our process to the optimum by
using control charts in Control Phase.
II. CONCLUSION
From the paper we come to understand that selection REFERENCES
of a Six Sig ma Project is Critical because we have to [1] The Certified Master Black Belt Book By T. M
Kubiak.
know the long term gains in executing these projects [2] The Six Sigma Hand Book by : Thomas Pyzdek and
and the activities done in each phase the basic building Paul Keller.
block is the define phase where the problem statement
is captured and then in measure phase data is collected