Six Sigma: Statistically Visualized

LOWER SPEC. LIMIT UPPER SPEC. LIMIT

PROCESS MEAN

1.5σ shift SIX SIGMA PROCESS 1.5σ shift

6σ 5σ 4σ 3σ 2σ 1σ 0 1σ 2σ 3σ 4σ 5σ 6σ
 Six Sigma Roadmap

Define
1
Build project from
nonconformance,
feedback & audits
Measure
SIX SIGMA IMPROVEMENT SIX SIGMA DESIGN (DFSS)
Collect measurements

Define Define
2
Measure Control/Verify Measure
Monitor live
Analyze dashboards Analyze

Improve Analyze Design

Analyze processes

Control online (OLAP) Verify

4

Improve/Design
Correct, design train &
3
document
 Design for Six Sigma (DFSS)

D EFINE Define project goals

Customer analysis/
risk assessment
Assemble team

M EASURE Capture vice of customer Determine project schedule Determine risk assessment

A NALYZE Develop CTQ’s Review project schedule Review risk assessment

D ESIGN Develop models Determine CTQ’s

O PTIMIZE Review CTQ’s Tolerance testing Design optimization

V ERIFY
Product comparison against
initial specifications
Document development
 Six Sigma 7X7 Toolbox

QUALITY CONTROL
DESIGN TOOLS STATISTIC TOOLS PROJECT TOOLS LEAN TOOLS CUSTOMER TOOLS MANAGEMENT TOOLS
TOOLS

Check forms (including

Robust design Factorial attempt Network plan Standardization Kano-Model Decision tree
measure plan)

Quality Function Development

Skill analysis Project & team description Waste analysis Requirement structuring Histogram Affinity diagram
(QFD)

TRIZ Regression analysis CTQ-Analysis Shortage analysis House of quality Pareto-Diagram Relations diagram

Pugh concept
Multivariate analysis Tree diagram Flow diagram Taguchi loss function Cause-and-effect diagram Tree diagram
selection

Statistical tests
FMEA / VMEA Skill analysis Supply chain matrix Customer interviews Graphic comparison Matrix diagram
(ANOVA, ANOM)

Fault tree analysis

Hypothesis testing Cost-benefit analysis Set-up time analysis Customer surveys Relations diagram Matrix-Data-Analysis
(FTA)

Tolerance design Gage R&R analysis Control charts Red-Tag-Analysis Conjoint analysis Control charts Network plan technique
 Six Sigma Methodology - DMAIC

Collect relevant data about the Determine the optimum values for key
process and the problem contributing process inputs

MEASUR IMPROV
E E

D M A I C

ANALYZ CONTRO
DEFINE
E L
Define the problem and the ideal in terms Identify the cause-effect relationship between Establish standards to sustain
of the target to achieve inputs and outputs. improvements in the long run.
 The 5 Phases of DMADV
01 02
DEFINE MEASURE
• Project team or determine • Identify & segment
project charter customers
• Determine objective & • Identify & analyze
scope of project customer req.
• Interface to other • Compare existing product
processes/define sector & with internal/external
provide resource benchmarking
• QFD for CTQ’s
03 04 05
ANALYZE DESIGN VERIFY
• Implement customer req. • Create detailed design • Review performance of the
into design concept • Develop robust design new product of the process
• Rate design concept (QFD, with optimal target (piloting)
TRIZ…) value/cost benefit ratio • Implementation of work
• Evaluation under • Apply DOE preparation & production
application of FMEA • Continuously monitor
(target costing…) results of new process