Chapter 10 - Six Sigma

Statistics (DPU, dpmo, off-

centering), DMAIC, Tools, 5S’s

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 Six Sigma Evolution
 Started as a simple quality metric at
Motorola (Bill Smith)
 Migrated to Allied Signal
 Picked up by General Electric
 Commitment by CEO Jack Welch
 Grown to be an integrated strategy for
attaining extremely high levels of quality

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 Statistics - DPU
 Defect
 Six Sigma: “any mistake or error passed on to
the customer” ???
 General view: any variation from specifications
 DPU (defects per unit)
 Number of defects per unit of work
 Ex: 3 lost bags ÷ 8,000 customers
= .00375
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 Statistics – dpmo (defects per
million opportunities)
 Process may have more than one
opportunity for error (e.g., airline baggage)
 dpmo = (DPU × 1,000,000) ÷ opportunities
for error
 Ex: (3 lost bags × 1,000,000) ÷
(8,000 customers × 1.6 average bags)
= 234.375
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 Statistics – dpmo (cont’d)

 May extend the concept to include higher

level processes
 E.g., may consider all opportunities for errors
for a flight (from ticketing to baggage claim)

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 Statistics - Off-Centering
 Represents a shift in the process mean
 Impossible to always keep the process
mean the same (this WOULD be perfection)
 Does NOT represent a change in
specifications
 Control of shift within ± 1.5 σ of the target
mean keeps defects to a maximum of 3.4
per million

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Statistics - Off-Centering
Source: Evans & Lindsay, The Management and Control of Quality, Southwestern, 2005
(cont’d)

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 k-Sigma Quality Levels
 Number of defects per million
 For a specified off-centering and
 a quality levels

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k-Sigma Quality Levels
Source: Evans & Lindsay, The Management and Control of Quality, Southwestern, 2005

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 Problem: “Is” ≠ “Should be”
 Problem solving may be seeking:
 Continuous incremental (kaizen)
 Breakthrough (hoshin)
 Common elements among pioneers
 Redefine and analyze the problem
 Generate ideas (tool: brainstorming)
 Evaluate and select idea(s)
 Implement idea(s)
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 Six Sigma Project Teams
 Champion – high level sponsor
 Master black belt – full time expert
 Black belt – fully trained (< 160 hrs.) expert
 Green belt – trained in introductory tools
and methodology
 Team member – selected from functional
areas impacted to support project
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 DMAIC
 Main problem solving methodology for 6
 Define
 Measure
 Analyze
 Improve
 Control

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 Tools & Techniques - List

1) Elementary statistical tools

2) Advanced statistical tools
3) Product design and reliability
4) Measurement
5) Process control
6) Process improvement
7) Implementation and teamwork
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 Tools & Techniques - 1
 Elementary statistical tools
 Basic statistics
 Statistical thinking
 Hypothesis testing
 Correlation
 Simple regression

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 Tools & Techniques - 2
 Advanced statistical tools
 Design of experiments
 Analysis of variance
 Multiple regression

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 Tools & Techniques - 3
 Product design and reliability
 Quality function deployment (QFD)
 Failure mode
 Effects analysis

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 Tools & Techniques - 4
 Measurement
 Process capability
 Measurement systems analysis

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 Tools & Techniques - 5
 Process control
 Control plans (Cp and Cpk)
 Statistical process control (SPC)

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 Tools & Techniques - 6
 Process improvement
 Process improvement methodology
 Process improvement planning
 Process mapping
 Mistake proofing or failsafing (Poka-Yoke)

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 Tools & Techniques - 7
 Implementation and Teamwork
 Organizational effectiveness
 Team assessment
 Facilitation tools
 Team development

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 Design for 6 - DFSS
 Complex engineering methodology
 Features use of:
 High-level architectural view
 CTQs (“critical to quality” characteristics)
 Technical requirements clearly specified
 Modeling and simulation approaches
 Prediction of defects and performance
 Variation analysis of subsystems and
components
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 Six  in Service Organizations
 More recent than in manufacturing
 50%+ of savings in non-manufacturing
 New term: “transactional Six Sigma”
 Main measures:
 Accuracy
 Cycle time
 Cost
 Customer satisfaction
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 Lean Operations and 6
 The 5 S’s
 Seiri (sort)
 Seiton (set in order)
 Seiso (shine)
 Seiketsu (standardize)
 Shitsuke (sustain)
 Visual controls
 Efficient layout and standardized work
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 Lean Operations and 6 (cont’d)

 Pull production
 Single minute exchange of dies (SMED)
 Total productive maintenance
 Source inspection
 Continuous improvement

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