Six Sigma

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What is Quality?

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 “We shall build good ships here;
at a profit if we can, at a loss if we must,
but always good ships.”
Newport News Shipbuilding & Drydock Company – USA

Sources: public
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Why should organizations care about
quality?

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Put a good person in a bad system and the bad system wins, no contest.
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The cost of quality is the expense of doing things wrong.
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 4 basic principles of Quality Management

 Customer satisfaction

 Prevention over inspection

 Management responsibility

 Continuous improvement

Sources: Supply Chain Risk Leadership Council

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The Goal then is to eliminate Defect…..

What is a Defect?

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What is Six-Sigma?

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 Six Sigma Overview

The goal of a SIX SIGMA program is to improve performance and customer delight by reducing the defect rate. 

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Central theme of Six-Sigma Process

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Central theme of Six-Sigma Process

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 Why Six-Sigma?

Sigma Input Qty Individual Process/Machine Output Output Qty

Yield
Level (nos) P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 (nos)

2σ 69.10000% 1000 691 477 330 228 158 109 75 52 36 25 25

3σ 93.33000% 1000 933 871 813 759 708 661 617 576 537 501 501

4σ 99.38000% 1000 994 988 982 975 969 963 957 951 946 940 940

5σ 99.97700% 1000 1000 1000 999 999 999 999 998 998 998 998 998

6σ 99.99966% 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000

ZERO DEFECT at a system level

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Key Focus of Six Sigma Process

Variability

Repeatability

Reproducibility

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DEFINE
• Project charter to define
the focus, scope, direction
and motivation.
• Voice of the customer to
understand feedback
from current/future
customers indicating
offerings that satisfy,
delight & dissatisfy them.
• Value stream map to
provide an overview of an
entire process, starting
and finishing at the
customer, and analyzing
what is required to meet
customer needs.
DMAIC Process
MEASURE ANALYSE
• Process map for recording • Root cause analysis (RCA)
the activities performed to uncover causes.
as part of a process.
• Failure mode and effects
• Capability analysis to analysis (FMEA) for
assess the ability of a identifying possible
process to meet product, service, and
specifications. process failures.
• Pareto chart to analyze • Multi-variation chart to
the frequency of detect different types of
problems or causes. variation within a process.
IMPROVE CONTROL
• Design of experiments • Quality control plan to
(DOE) to solve problems document what is needed
from complex processes to keep an improved
or systems where there process at its current
are many factors level.
influencing the outcome
and where it is impossible • Statistical process control
to isolate one factor or (SPC) for monitoring
variable from the others. process behavior.
• Kaizen event to introduce • 5S to create a workplace
rapid change by focusing suited for visual control.
on a narrow project and
using the ideas and • Mistake proofing (poka-
motivation of the people yoke) to make errors
who do the work. impossible or
immediately detectable.
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Value Stream Mapping

Value Stream Maps help Visualize Problems

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 Process Capability Analysis

Process Capability Analysis help Visualize and Understand the Extent of Problems

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 Root Cause Analysis
5 Whys Ishikawa (Fish Bone) Diagram

Techniques help get to the root of a problem

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Case Discussion

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Questions?

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 Assignment
1. Evaluation 1  Multiple Choice Questions.

2. Evaluation 2  Case Work

Case: Internet Speed Test

• Go to www.speedtest.net and conduct speed test of your internet broadband service provider.
• Take 25-30 data points of download speed (Mbps) at different times during the day.
• Provide your detailed observations and assessment on –
a) Mean and Standard Deviation of the data points.
b) Define your acceptable target and range limits (+-) as committed by your service provider (airtel,
hatchway, Jio etc.) and calculate DPMO (defects per million opportunities) of this process.
c) Use DMAIC process to identify root causes of the defects and suggest improvements/controls to
make it 6 sigma process.

Completion deadline – Monday, 13 April 2020 @ 8am

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