Motorola systematically improved processes by eliminating defects Bill smith in 1986

6 Sigma & Standard Deviation

Signifies standard deviation of a population

Standard Deviation indicates variation or inconsistency in any group of items Example Fast Food----Warm one day, Lukewarm on other day, is variation Airport …..Luggage in 5 minutes or 15 minutes

INSPIRED BY

Quality Control

TQM

Zero Defects

Asserts

Continuous efforts to reduce Variation in process output is key to business success

Manufacturing and business processes Can be measured ,analyzed ,improved And controlled

Succeeding at achieving sustained quality Improvement requires commitment from the Entire organisation, particularly from top Level management

Refers to the ability of highly capable processes to Produce output within specification. In particular, Processes that operate with six sigma quality Produce at defect level below 3.4defects per million Opportunities (DPMO). Six Sigma’s implicit goal is to improve all Processes to that level of quality or better

Six Sigma stands for Six Standard Deviations from mean.
(Sigma is the Greek letter used to represent standard deviation in statistics)

Six Sigma methodology provides the techniques and tools to improve the capability and reduce the defects in any process.

methodology

DMAIC

DMADV

methodology

DMAIC

Define Measure Analyze Improve Control

methodology
DMAIC
Define Measure Analyze Improve Control

Define: the process improvement goals that are consistent with customer demand and enterprise strategy

methodology
DMAIC
Define Measure Analyze Improve Control

Measure: the current process and collect relevant data for future comparison

methodology
DMAIC
Define Measure Analyze Improve Control Analyze: to verify relationship and causality of factors. Determine what the relationship is,and attempt to ensure that all factors have been considered

methodology
DMAIC
Define Measure Analyze Improve Control

Improve: or optimize the process based upon the analysis using techniques like design of experiments

methodology
DMAIC
Control: to ensure that any variances are
Define Measure Analyze Improve Control corrected before they result in defects. Set up pilot runs to establish process capability, transition to production and thereafter continuously measure the process and institute control Mechanisms

methodology

DMAIC

Define Measure Analyze Improve Control

methodology
DMADV
Define Measure Analyze Design Verify
Define:
the goals of design activity that are consistent with customer demands and enterprise strategy

methodology
DMADV
Define Measure Analyze Design Verify Measure:
and identify CTQs (Critical to qualities), product capabilities production process capability and risk assessment

methodology
DMADV
Define Measure Analyze Design Verify
Analyze To develop and design alternatives, Create high level design and evaluate Design capability to select the Best design

methodology
DMADV
Define Measure Analyze Design Verify
Design Details, optimize the design, and plan For design verification. This phase may Require simulations

methodology
DMADV
Define Measure Analyze Design Verify
Verify The design, setup pilot runs, implement Production process and handover to process owners

Other methodologies
DCCDI CDOC DCDOV CDOC DMADOV DMEDI IDOV I2DOV
Define, Customer Concept, Design and Implement Conceptualize, Design, Optimize, Verify Define, Concept,Design, Optimize, Verify Conceptualize, Design, Optimize, Verify Define, Measure, Analyze, Design, Optimize, Verify

Define, measure, Explore, Develop,and Implement Identify, Design, Optimize and Validate Invent, Innovate, Develop, Optimize, Validate

Implementation Roles

IMPLEMENTATION ROLES

YELLOW BELTS GREEN BELTS

BLACK BELTS

EXPERTS
MASTER BLACK BELTS

CHAMPIONS
EXECUTIVE LEADERSHIP

Benefits

John Chambers CEO, CISCO

Generate Sustained Success

One can be out of business. Only way to continue double Digit growth and retain a hold on Shifting market is to constantly Innovate and remake the organization

Benefits

Sets Performance Goal for Everyone

Getting everyone working in the same Direction and focusing on a common Goal………Customer Performance……..99.9997% Excellent performance look pretty week

Benefits
Performance Goals—what you’d Get For every 300000 letters delivered with 99% with 6 sigma 1 misdelivery

Sets Performance Goal for Everyone

3000 misdeliveries

Out of 500000 computer restart 4100 crashes < 2 crashes

For Every week of TV broadcasting 1.68 hrs of dead air 1.8 seconds

Benefits

Jack Welch---GE

Enhances Value to Customers

We want to make our quality so Special ,so valuable to our customers, So important to their success that our Products become their only real Value choice

Benefits

Accelerate the Rate of Improvement

Motorola
Goal of 100x improvement in 4 years Sets an example for ambitious, driven Organisation to emulate

Benefits

Promotes Learning and Cross Pollination

Allied Signal- honeywell
Everyone talks about learning But few succeed in weaving it into the Fabric of everyday life for so many Employees…GE plastics to GE Capital

Benefits

Allied Signal- Honeywell Execute Strategic Change
Introducing new products, launching new Ventures, entering new markets, acquiring New organizations- what were occasional Business activities are now daily events in many companies

Benefits
Continuous Improvement

Process Design/ Resign

Statistical Process Control

Analysis Of Variance

Process Management

Balance Scorecard
of ign ents Des rim e Exp

Creative Thinking

Voice of The Customer

6 sigma initiative include

E-commerce and Services Enterprise Resource Planning Lean Manufacturing Customer Relationship Management Strategic Business Partnerships Knowledge Management The process- Centered Organization Globalization Just in Time inventory/Production

6 themes of 6 sigma
Theme One: Genuine Focus on Customer

Theme Two:
Data and Fact Driven Management

Theme Thee: Process Focus, Management and Improvement

Theme Four: Proactive Management

Theme Five: Boundary less Collaboration

Theme Six: Drive for Perfection, Tolerance for Failure

?