SIX

SIGMA
AGENA ESTEBAN GUEVARRA
What is Six Sigma?
 Six Sigma is a disciplined,
statistical-based, data-driven
approach and continuous
improvement methodology for
eliminating defects in a product,
process or service.
 It was developed by Motorola and
Bill Smith in the early 1980’s
based on quality management
fundamentals, then became a
popular management approach at
General Electric (GE) with Jack
Welch in the early 1990’s.
What is Six Sigma?
 Sigma represents the population
standard deviation, which is a
measure of the variation in a data
set collected about the process. If
a defect is defined by
specification limits separating
good from bad outcomes of a
process, then a six sigma process
has a process mean (average) that
is six standard deviations from
the nearest specification limit.
What is Six Sigma?
 Six Sigma can also be thought of
as a measure of process
performance, with Six Sigma
being the goal, based on the
defects per million.
 Once the current performance of
the process is measured, the goal
is to continually improve the
sigma level striving towards 6
sigma.
The martial arts belt structure is used to
recognize proficiency in training and application
in Six Sigma, using the following colors:
 White Belt – Overview, DMAIC,  Black Belt – Green Belt + advanced
Define Phase statistical analysis and
experiments, change management,
 Yellow Belt – White Belt + process
non-normal distributions
mapping, data collection and
charting, assisting with a project  Master Black Belt – Black Belt +
Design for Six Sigma, more
 Green Belt – Yellow Belt + Project
advanced statistical analysis,
leader, core Six Sigma tools (Gage
unique tools for specific industries
R&R, SPC, Capability, ANOVA,
and processes, working with
Regression), change management,
leadership, implementing
hypothesis tests and more
successful improvement program
 AUDIT
CHECKS
WHAT IS AUDITING?
 Auditing is defined as the on-site
verification activity, such as inspection or
examination, of a process or quality
system, to ensure compliance to
requirements. An audit can apply to an
entire organization or might be specific
to a function, process, or production
step. Some audits have special
administrative purposes, such as auditing
documents, risk, or performance, or
following up on completed corrective
actions.
THE THREE DIFFERENT TYPES OF AUDITS
A process audit may:
Process audit
 Check conformance to defined requirements
This type of audit verifies that processes such as time, accuracy, temperature,
are working within established limits. It pressure, composition, responsiveness,
amperage, and component mixture.
evaluates an operation or method against
 Examine the resources (equipment,
predetermined instructions or standards materials, people) applied to transform the
to measure conformance to these inputs into outputs, the environment, the
standards and the effectiveness of the methods (procedures, instructions) followed,
and the measures collected to determine
instructions. process performance.
 Check the adequacy and effectiveness of the
process controls established by procedures,
work instructions, flowcharts, and training
and process specifications.
THE THREE DIFFERENT TYPES OF AUDITS
Product audit:
This type of audit is an examination of a particular product or
service, such as hardware, processed material, or software,
to evaluate whether it conforms to requirements (i.e.,
specifications, performance standards, and customer
requirements).
THE THREE DIFFERENT TYPES OF AUDITS
System audit:
An audit conducted on a management
system. It can be described as a
documented activity performed to verify,
by examination and evaluation of
objective evidence, that applicable
elements of the system are appropriate
and effective and have been developed,
documented, and implemented in
accordance and in conjunction with
specified requirements.
Quality management system audit evaluates
an existing quality management program to
determine its conformance to company
policies, contract commitments, and
regulatory requirements.
Environmental system audit examines
an environmental management system
Food safety system audit examines a food
safety management system
Safety System audits examine the safety
management system.
WHAT ARE THE FOUR PHASES OF AN
AUDIT CYCLE?

1. Audit
planning and
preparation
2. Audit execution
3. Audit reporting
4. Auditfollow-up
and closure
ACCEPTANCE
SAMPLING
What is Acceptance Sampling?
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.
Acceptance sampling is employed when
one or several of the following hold:
 Testing is destructive
 The cost of 100% inspection is very high
 100% inspection takes too long
Procedure of Acceptance Sampling:
TERMINOLOGIES
 Acceptable Quality Level (AQL):
It is the desired quality level at which probability of a acceptance is high. It
represents maximum proportion of defectives which the consumer finds
acceptable or it is the maximum percent defectives that for the purpose of
sampling inspection can be considered satisfactory.

 Lot Tolerance Percent Defective (LTPD) or Reject able Quality Level (RQL):
It is the quality level at which the probability of acceptance is low and below
this level the lots are rejected. This prescribes the dividing line between
good and bad lots. Lots at this quality level are considered to be poor.

 Average outgoing Quality (A.O.Q):

Acceptance sampling plans provides the assurance that the average quality
level or percent defectives actually going to consumers will not exceed
certain limit.
Advantages of Acceptance Sampling:
 Items of destructive nature during inspection can be
inspected by sampling only.
 Economy of time and money in comparison to 100%
inspection.
 Problem of inspection fatigue occurring in 100% inspection
is eliminated.
 Small inspection staff required.
 Due to quick inspection, scheduling and delivery times are
improved.
 Can exert more effective pressure on quality improvement
than the rejection of individual items.
Disadvantages of Acceptance Sampling
 There are risks of accepting bad lots and rejecting good
lots.
 Less information is generated about the product and the
process that manufactured the product.
 Acceptance sampling requires planning and
documentation of the acceptance sampling procedure.