Professional Documents
Culture Documents
CSUN Management
Six Sigma Quality
Engineering
Week 2
Introduction to Six Sigma
Macro model of Six Sigma Management
Chapters 1,2 & 3 Outline
Y= f (X)
• Y X1 . . . X N
• Dependent Independent
• Output Input-Process
• Effect Cause
• Symptom Problem
• Monitor Control
Nonconformities
Nonconformities
PMO
PMO
• Allied Signal The sigma scale
2 308,770 of measure is
• Boeing perfectly
3 66,811 correlated to
• Caterpillar such
characteristics
• General Electric 4 6,210 as defects-per-
unit, parts-per
• John Deere & Co 5 233 million defective,
and the
• Lockheed Martin 6 3.4 probability of a
failure/error.
• Motorola
Process
Process Parts
Partsper
perMillion
• Polaroid Million
Capability
Capability Opportunities
Opportunities
• Sony
Timeline of Six Sigma Management
Feedback Loops
• A feedback loop relates information about outputs from any stage
or stages back to another stage or stages to make an analysis of
the process.
Feedback Loop
Voice Of the Customer (VOC)
Nominal Value
Voice Of the Customer (VOC)
Therefore
Producers should bring forth these products in a
manner that minimizes cost and cycle time and
maximizes profit
Voice Of the Customer (VOC)
Process Owner
• Is the manager of a process. The process owner should be identified and involved in
all Six Sigma projects relating to the process owner area. A process owner has the
following responsibilities:
1. Empower employees to follow and improve best practice methods
2. Accept and manage the improved process after completion of the Six Sigma project
3. Understand how the process works, the capability of the process, and the relationship of
the process to other processes in the organization
Technical terminology of Six Sigma
Management
Critical-To-Quality (CTQ): Is a measure of what is important to a
customer.
Defect: Is a nonconformance on one of many possible quality
characteristics of a unit that causes customer dissatisfaction
Defects per Million opportunities (DPMO): A quality metric often
used in the Six Sigma process. It is calculated by the number of
defects observed divided by the number of opportunities for
defects compared to 1 million units.
Yield: Is the proportion of units within specification divided by
the total number of units.
Rolled Throughput Yield (RTY): Is the product of the yields from
each step in a process.
Six Sigma Methodology (DMAIC)
Project Name:
Estimated Actual
DMAIC PROCESS AND PHASE GATE completion completion Status
date date
Define
Met Define Phase Criteria No
Define Customers and Requirements (C TQs)
Develop Problem Statement, Goals and Benefits
Identify C hampion, Process Owner and Team
Define Resources
Evaluate Key Organizational Support
Develop Project Plan and Milestones
Develop High Level Process Map
Measure
Met Measure Phase Criteria No
Define Defect, Opportunity, Unit and Metrics
Detailed Process Map of Appropriate Areas
Develop Data Collection Plan
Validate the Measurement System
C ollect the Data
Begin Developing Y=f(x) Relationship
Determine Process Capability and Sigma Baseline
Six Sigma Methodology (DMAIC)
Analyze
Met Analyze Phase Criteria No
Define Performance Objectives
Identify Value/Non-Value Added Process Steps
Identify Sources of Variation
Determine Root C ause(s)
Determine Vital Few x's, Y=f(x) Relationship
Improve
Met Improve Phase Criteria No
Perform Design of Experiments
Develop Potential Solutions
Define Operating Tolerances of Potential System
Assess Failure Modes of Potential Solutions
Validate Potential Improvement by Pilot Studies
C orrect/Re-Evaluate Potential Solution
Control
Met Control Phase Criteria No
Define and Validate Monitoring and C ontrol System
Develop Standards and Procedures
Implement Statistical Process C ontrol
Determine Process C apability
Develop Transfer Plan, Handoff to Process Owner
Verify Benefits, C ost Savings/Avoidance, Profit Growth
C lose Project, Finalize Documentation
C ommunicate to Business, C elebrate
Six Sigma Macro Model (Dashboards)
KEY DIAGNOSTIC
STAKEHOLDER
MEASUREMENT MEASUREMENT
2005 Actual Actual/ JAN FEB MAR APR
Plan
Cum Actual 9,080 18,847 29,546 40,519
Cumulative Sales 105792
Growth Over Market Cum Plan 9,702 19,433 29,164 38,846
Actual 6.3% 28.4% 22.0% 23.1%
CFROGC 20.9%
Plan 21.9% 19.1% 22.8% 16.9%
Actual 150 152.6 140.9 146.3
DOH 133
Plan 139.5 137.5 136.3 133.5
Actual 41.9 46.8 48.6 47.4
DSO 45
Plan 43.3 43.5 43.5 44
Actual 47 57 78 42
DPO 27
Plan 50 50 50 50
Capital
SHAREHOLDERS Cum Actual 3 501 1,701
Expenditures 1,517
($ 000) Cum Plan 3 389 409
Cum Actual 2.3% 11.4% 12.2% 13.0%
Operating Margin 12.0%
Cum Plan 14.5% 13.4% 14.0% 13.2%
Actual 0.5% 2.0% 0.7% 1.2%
Productivity -3.3%
Plan 0.7% 0.7% 0.7% 0.7%
Material Cost Out ($ Cum Actual $280 $653 $1,092 $1,530
$2,320
000's) Cum Plan $105 $160 $265 $370
Factory Cost Out ($ Cum Actual $26 $46 $76 $81
$1,000
000's) Cum Plan $13 $26 $39 $52
Actual 3.5 3.5 3.5 3.1
Lean Score 3.5
Plan 3.5 3.5 3.5 3.5
Six Sigma Macro Model (Dashboards)
Actual 56.4% 63.7% 60.6% 65.6%
Product OTD 62.1%
Plan 60.0% 63.0% 65.0% 68.0%
Past Due $ Actual $8,262 $8,100 $6,973 $5,886
$7,213
($ 000's) Plan $8,000 $7,500 $7,000 $6,500
Actual 13.1% 6.2% 7.6% 4.8%
MPS OTD 14.6%
Plan 0.0% 0.0% 10.0% 11.0%
Actual 60.5% 53.5% 60.0% 55.4%
Supplier OTD 57.3%
Plan 57.0% 58.0% 59.0% 60.0%
CUSTOMERS
3 Month Rolling Actual 2012 1534 1783 2000
Product Quality 2706
(DPPM) Plan 3000 3000 3000 3000
3 Month Rolling Actual 8765 8488 18974 1087
Supplier Quality 9594
(DPPM) Plan 12000 10000 9500 9000
Dev. Program Actual 75.0% 66.7% 42.9% 66.7%
50.0%
Milestone OTD Plan 75.0% 75.0% 75.0% 75.0%
OCA Action Item Actual
0.0%
OTD Plan 0.0% 0.0% 0.0% 0.0%
Employee Survey Actual 10.0%
EMPLOYEES 80.0%
Action Item OTD Plan 0.0% 0.0% 0.0% 10.0%
Actual 8.8 4.7 2.8 2.3
Safety TCIR 2.0
Plan 5.0 4.0 2.9 2.7
Spend/Strategic Actual
SUPPLIERS $0
Supplier ($000) Plan $0 $0 $0 $0
Environ Audit Action Actual 100.0% 100.0% 100.0%
1
Item OTD Plan 0 1 1 1
COMMUNITY Charitable Cum Actual $648 $1,195 $1,893 $2,406
Contributions $8,311
($ 000's) Cum Plan $708 $1,416 $2,124 $2,832
Plant Performance Dashboard
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Oct
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Oct
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S u p p l ie r F a il u r e U . S . B a l l C o r p . s t o c k i n g p r o g r a m ( a n o t h e r h i g h v o l u m e lo w c o s t s u p p li e r ) 1 1 /3 0 /2 0 0 4 A c c e s s d a t a b a s e fo r p la n n e rs b a c k lo g L e b e ts a m e r/ M c B ro o m O n - g o in g d i d n o t m a t c h G u l fs t r e a m 's P O d a t e s ) . s c ru b V 2 2 s o u rc e in s p e c t io n a t T P T S Q E
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T. M endoza /
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S u p p l ie r F a il u r e R a t io n a liz i n g s u p p lie r b a s e ( A l p in e , W C L , B l e v i n s , V i k i n g ) Q u a lit y m g r . O n g o in g C o n t i n u e C e r t i fi e d S u p p l i e r P r o g r a m r o l lo u t S Q E s O n g o in g 3 3 3 3 3 3 U U U n n n i it tis ts s d d d e e et t e te er r mrm m i in ni ne e ed d d t t o to o b b be e e C C C u u us s st t o to o m m m e e er r r RR R e e es s sp p po o on n n s s si ib bi b i il lii i lt t iy ty y o o or r r NN N o o o F F F a a a u u ul lt tl t F F F o o uo u un n n d d d
S u p p l ie r F a il u r e R a t io n a l iz i n g s u p p l ie r b a s e ( A l p in e , W C L , B l e v i n s , V i k i n g ) Q u a lit y m g r . O n g o in g S u p p o rt o f s c h e d u le t o o l L e b e ts a m e r/ M c B ro o m C o m p le te 3 3 U n i t s d e t e r m in e d t o b e C u s t o m e r R e s p o n s i b i li t y o r N o F a u l t F o u n d
P l a n n in g P r o b l e m S u p p l ie r s n o w h a v e fo r w a r d v is i b i li t y fo r s u b - c o n t r a c t P O 's t o p la n t h e i r c a p a c it y n e e d s . T. M endoza
T. M endoza C o m p le te S u p p o rt o f s c h e d u le to o l L e b e ts a m e r / M c B r o o m C o m p le t e 1 1 1 7 7 7 U U U n n n i it tis ts s n n n o o ot t t e e ev v va a a l lu ul u a a at t e te ed d d a a as s s o o o f f f t t h th h e e e d d d a a at t e te e o o of f f t t h th hi is si s r r e re e p p po o o r r t r t i tin ni ng g g
P la n n in g P r o b l e m S u p p l ie r s n o w h a v e fo r w a r d v is i b i li t y fo r s u b - c o n t r a c t P O 's t o p la n t h e i r c a p a c it y n e e d s . C o m p le te 1 7 U n i t s n o t e v a lu a t e d a s o f t h e d a t e o f t h i s r e p o r ti n g
C M C a d d e d a s C e r t i fie d S u p p l ie r - 6 2 % o f C M C p a r t s a r e n o w s h i p t o s t o c k a n d a t h r id o f a ll M endoza 4 4 4 UU U n n ni it tis ts s w w w e e e r r e re e d d de e et t e te er r mrm m i in ni n e e ed d d t t o to o b b be e e EE E a a a t t o to on n n’ ’s s’ s R R R e e es s sp p po o o n n ns s si ib bi b i il l ii ilt ti y ty y
C M C a d d e d a s C e r t i fie d S u p p l ie r - 6 2 % o f C M C p a r t s a r e n o w s h i p t o s t o c k a n d a t h r id o f a ll
r e c i e p t s a r e s h ip t o s t o c k .
M en d o z a
R e -o r g a n i z a t i o n o f m a n u fa c t u rin g a n d s u p p ly c h a in . H a r ris C o m p le te 4 U n i ts w e r e d e t e r m i n e d t o b e E a t o n ’ s R e s p o n s i b il i t y
r e c i e p t s a r e s h ip t o s t o c k .
C o m p le te
C o m p le te R e -o rg a n i z a t i o n o f m a n u fa c t u rin g a n d s u p p ly c h a in . H a r ris C o m p le t e D D D P P P P P P M M M CC C a a al lc cl c. . . = = = 2 2 2 1 1 1/ / 6 /6 6 6 6 6 8 8 85 5 5 * * * 1 1 1 , , 0 0, 00 0 00 0 0 , , 0 0, 00 0 0 0 0 0 = = = 3 3 3 1 1 1 4 4 41 1 1
D P P M C a lc . = 2 1 /6 6 8 5 * 1 ,0 0 0 ,0 0 0 = 3 1 4 1
UU U n n ni it tis st s d d de e e t t e et er r mrm m i i n ni n e e ed d d t t o ot o b b be e e C C C u u u s s st t o to om m m e e er r r RR R e e e s s sp p p. . . o o o r r r N N N o o o F F F a a au u u l lt t l t F F F o o o u u un n n d d d n n n o o o t t t u u us s se e ed d d i in ni n c c ca a al lc cl cu u ul la al at t i tio oi on n n
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RR ee cc ee iivvee dd ee aa rr llyy oo ww nn ee rrss tt oo ee nn ss uu rr ee tt hh ee yy uu nn dd ee rr ss tt aa nn dd tt hh ee nn ee ww fif ivvee dd aa yy ee aa rr llyy ,, oo nn tt iimm ee dd ee lliivvee rryy ww iinn dd oo ww .. CC oo mm pp llee tt ee
RR ee cc ee iivvee dd ee aa rr llyy MM ee tt rriicc ee aa rrllyy tt oo llee rr aa nn cc ee cc hh aa nn gg ee dd frfr oo mm iinn ffiinn iitt ee tt oo 55 dd aa yy ss .. PP oo lliicc yy ee nn ffoo rr cc ee mm ee nn tt MM ee nn dd oo zz aa OO nn gg oo iinn gg
TT .. MM ee nn dd oo zz aa 55 00 %% cc oo mm pp llee tt ee
SS uu pp pp lliiee rr FF aa iilluu rree UU .. SS .. BB aa llll CC oo rrpp .. ss tt oo cc kk iinn gg pp rroo gg rraa mm (( aa nn oo tt hh ee rr hh iigg hh vvoo lluu mm ee lloo ww cc oo ss tt ss uu pp pp lliiee rr)) 11 11 // 33 00 // 22 00 00 44
TT .. MM ee nn dd oo zz aa //
SS uu pp pp lliiee rr FF aa iilluu rree RR aa tt iioo nn aa lliizz iinn gg ss uu pp pp lliiee rr bb aa ss ee (( AA llpp iinn ee ,, WW CC LL ,, BB llee vv iinn ss ,, VV iikk iinn gg )) QQ uu aa lliitt yy mm gg rr .. OO nn gg oo iinn gg
PP llaa nn nn iinn gg PP rr oo bb llee mm SS uu pp pp lliiee rrss nn oo ww hh aa vv ee ffoo rrww aa rr dd vviiss iibb iilliitt yy fofo rr ss uu bb --cc oo nn tt rraa cc tt PP OO 's's tt oo pp llaa nn tt hh ee iirr cc aa pp aa cc iitt yy nn ee ee dd ss .. TT .. MM ee nn dd oo zz aa CC oo mm pp llee tt ee
CC MM CC aa dd dd ee dd aa ss CC ee rrtt iififiee dd SS uu pp pp lliiee rr -- 66 22 %% oo ff CC MM CC pp aa rr tt ss aa rr ee nn oo ww ss hh iipp tt oo ss tt oo cc kk aa nn dd aa tt hh rr iidd oo ff aa llll MM ee nn dd oo zz aa
rr ee cc iiee pp tt ss aa rr ee ss hh iipp tt oo ss tt oo cc kk .. CC oo mm pp llee tt ee
Questions? Comments?