Define Understanding Six Sigma

Define Phase
• Pareto Analysis

• Process Mapping

• Logic Tree

• 3/5 Why Analysis

• RTY

• QFD

• FMEA

• Brainstorming
Define Understanding Six Sigma

Pareto Analysis : The Origin of the Tool lies with the Italian Economist Vilfredo
Pareto. Pareto Principle is also known as 80/20 .20% of items purchased by the
company accounts for 80% of the value 1st Item in the figure below indicates the
highest no of faults

Pareto Charts are a type of bar chart in which the horizontal axis represents categories
of interest, rather than a continuous scale. The categories are often "defects." By ordering
the bars from largest to smallest, a Pareto chart can help you determine which of the defects
comprise the "vital few" and which are the "trivial many." A cumulative percentage line helps
you judge the added contribution of each category. Pareto charts can help to focus
improvement efforts on areas where the largest gains can be made.
Pareto chart can draw one chart for all your data (the default), or separate charts for groups
within your data.

Example :The company you work for manufactures metal bookcases. During final
inspection, a certain number of bookcases are rejected due to scratches, chips, bends, or
dents. You want to make a Pareto chart to see which defect is causing most of your
problems. First you count the number of times each defect occurred, then you enter the
name of the defect each time it occurs into a worksheet column called Damage.
Define Understanding Six Sigma

Damage Counts • Choose Stat > Quality Tools > Pareto Chart.
Scratch 274 • Choose Chart defects data in and enter
Scratch 59 Damage. Click OK.
Bend 19
Graph window output
Chip 43
Dent 4
Scratch 8
Chip 6
Scratch 10
Define Understanding Six Sigma

Process Mapping
• Process mapping is used to document process to examine part and information flow.
• It is a key tool in identifying opportunities for improvement.

The Process Mapping Method

• Define the Process boundary. (General area or specific process you intend to
improve)
• Brainstorm and order process steps with your team.
• Code activities using symbols for easy analysis.
• Walk through the process to validate map.
• Add key process metrics
- yield, costs, rolled throughput yield, scrap, overtime $, capacity, %schedule, %OTD
• Analyze map for key business issues -could be in the areas of :
- Process loss or waste
- Cycle time improvements
- Quality improvements
- Flow improvements
Define Understanding Six Sigma

Process Mapping [ex] Vehicle Purchasing

Meeting Look around Look around

Car Shop arrival Small Talk
Salesman first car second car

Look around Trial No Shop around

third car Driving? for another shop
Yes No
Operation
Receive Trial Whether you Yes Decide Review the
key and Tag Driving buy or not? to buy sales manager
Decision
Decide
Contract Value
Delay

Decide the Whether you No Visit another measurement

Price purchase another or not? car shop
Yes
Storage
No
Decide Review the Decide Yes Make out
Reasonable
to buy sales manager the price price? final contract

w
Transmission
Get a Credit Stand by Drive the
loan check for a loan new car
Define Understanding Six Sigma

Process Mapping [ex] Refrigerator - R1 Line Rolled Throughput Yield

Door Ass’y 89.7%

D/Plate plate/paint

99.0%

D/Liner extrusion/mold Door forming Door assembly

99.7% 93.4% 97.3%

99.6% 81.0%

I/Case extrusion/mold Case forming Cycle assembly

83.8%
97.7%

Front - CTQ, L painting O/Case, B/Plate LQC & appearance

99.2% 91.7% 96.5%
Case Ass’y 73.4%
Output
Rolled Though put Yield = 73.4% ×
89.7% × 97.7% × 83.8%× 96.5% = 52.0%
▲ ▲ ▲ ▲ ▲
Case Door Cycle assembly LQC& appearance
Define Understanding Six Sigma

Logic Tree (Structure Tree)

• Used to break down problem into manageable groups to identify root cause or area
of focus.
• Breakdown the problem on the base of MECE
- MECE - Mutually Exclusive Collectively Exhaustive
Mutually Exclusive : When a Problem is broken into further sub parts there should not
be anything common among the factors.
Collectively Exhaustive : Also there should be nothing left to represent the Main factor
Why
Electromagnetic Losses

Lamination Inductance
Why Mechanical OD
Rotor
Endrings Area A Core length

RPM Stator
Area B
Assembly
6σ is a kind of type which can improve the problem (RPM) by practicing improvement
activity for the lower level displayed in the long run
Define Understanding Six Sigma

5 Why Analysis : Five Why analysis is done to determine the root cause of the
Problem . It is a kind of brainstorming to reach the root cause of the Problem.

It is Observed that by the time you arrive at the 5th Why the solution of the
Problem is with you. It is not essential to ask why 5 times, you can locate the root
cause at the 3rd or 4th Why also..
Define Understanding Six Sigma

Rolled Throughput Yeild

RTY : Rolled throughput Yeild : It is the Probability that the product will pass

through all the stages without any rejection / rework.

RTY is calculated by calculating the YFT’s of Individual stages.

RTY = YFT1 * YFT2 * ……… YFTn ,

where YFT’s are the First time yields of the Individual Stages/Process
connected in series.

YNA = Normalized Yield = ( RTY of the line )1/no. of stages in Line

YNA gives the average yield of line . This is used to calculate when we have

to compare the performance of two lines on the basis of RTY.

Define Understanding Six Sigma
RTY is the probability of going through all the processes with zero-defect the first
time . Also, it provides an indication of opportunities to reduce the waste.

To increase productivity
Goal through Quality Improvement
Input
-Process 1: (Acceptance-
rate:99.0%) Overall process’s defect, m/c
Target trouble, No work,L/B,Model
-Process 2 (92.0%) Change Loss,Non-value added work

-Process 3 (97.0%)
Tool 6 Sigma

Final Inspn.
(97.0%) TDR, 6 Sigma, NWT,
Activity
One man one project
Un-controlled Total Process Final
Loss Defect-rate Product
- Process defect rate
- Self & sequential inspection
To improve all
RTY = 0.99×0.92×0.97×0.97= 85.7 % the hidden defects of all
* RTY : Rolled Throughput Yield the processes
Define Understanding Six Sigma

Yield First Time

1000 Are 820

Painted Yes
the parts
Components
Good ?

No

100 Can 30 Rework &

the parts be Pass-on
Rework & Yes repaired ? Yes ( Paint Touch up)
Reprocess
( Rust, Chemical Wash) 50
No

Scrap
(Dent)
Define Understanding Six Sigma

First Time Yield Rolled Throughput Yield Normalised Yield

YFT = S/U YRT = YFT1 x YFT2 x YFT3 YNA = (YRT)**1/Opp

YFT = First Time Yield YRT = Rolled Throughput YNA = Normalized Yield
S = No. of units that pass the yield Opp = Number of opportunities
first time YFT1,YFT2,… = First Time Yield of
U = No. of units tested each process

•YRT gives the •YNA us average

probability of going yield of processes.
YFT gives the through all the •YNA allows for
processes with zero
probability of going calculation of Z value
defects in the first time.
•YRT provides an of processes.
through one process •YNA allows for
indication of
with zero defects. opportunities to comparison
reduce waste. between processes.
Define Understanding Six Sigma

QFD : Quality Function Deployment ( What Customer Wants )

It is defined in two steps :

a) Converting customer’s Voice into Engineers Voice

b) Converting Engineers voice into Technical CTQ’s & CTP’s

QFD is tool which is used to generate data in the form of taking feedback from the
customer through quality matrix, converting those requirements into Tech changes
in the Process through Quality Matrix.
• Identify key consumer cues by reviewing market, reliability requirements, general
requirements and current quality issues.
• Rank cues by importance and translate them into technical specifications required to meet
customer cues. Rank technical specifications by impact on customer cues and translate
them into potential part characteristics(CTQ’S).
• Rank part characteristics by impact on meeting technical specifications(CTQ’S)

QFD translates the Voice of the Consumer into the Voice of the Engineer.
Define Understanding Six Sigma

QFD : Sub Process 1 : To Convert Consumer’s Voice into Engineer’s Voice

Engineer's Voice

Priroty

System for
Capacity of

HE Coils
Charging

Fins per
Ranking

Type of

Blower
/Scroll
Comp

Motor

Inch
Gas
Less Price 9 3 1 1 1 10
Low Noise 3 9 9 1 1 6
Requirement
Customer's

Air Flow 1 1 9 3 3 5
Less Power 9 9 1 3 1 8
More Cooling 9 3 3 9 9 3
Rating 212 170 126 82 66
Define Understanding Six Sigma

QFD : Sub Process 2 : To Convert Engineer’s Voice into Potential CTP’s & CTQ’s

Comp Specifications

EER Specifications

HE Design Spec to
Variation less than
Gas Charging Qty

be maintained
Priroty

KW Rating
Ranking

5mg
Type of Comp 9 1 3 3 1 212
Engineer's Voice

Capacity of Motor 1 9 3 1 1 170

Blower /Scroll Design 1 1 9 1 3 126

System for Gas Charging 1 1 1 9 3 82

HE Coils Fins per Inch 1 1 1 3 9 66

2352 2016 2428 1868 1600
Define Understanding Six Sigma

FMEA : Failure Mode Effect Analysis ( What Customer Doesn’t want )

It gives you possible reasons in which a given Process / Design of part of a

Product can Fail. To every Failure Mode we associate RPN Number

RPN : Risk Priority Number = Severity * Occurrence * detection

Rating Scale (1 ~ 10) (1 ~ 10) (1 ~ 10)

1 : If the Problem is Less Severe
Severity
10 : If the Problem is Life Threatening.
1 : If the Problem has chances of less occurrence
Occurrence
10 : If the Problem has more chances of occurrence

Detection 1 : If the Problem is easily detectable.

10 : If it is difficult to locate/detect the Problem

FMEA is used to proactively identify and rank risks in a product design and
assign appropriate actions to be taken to prevent the failure mode.
Define Understanding Six Sigma

FMEA Process

• Brainstorm potential failures of the product design.

• Assign severity and probability (likelihood of occurrence) ratings to each

potential failure mode.

• Determine existing control measures being taken to eliminate significant

failure modes.

• Develop actions to be taken to eliminate or reduce risk on all remaining

significant failure modes.

Define Understanding Six Sigma

Brainstorming : It is Discussion among the Process Experts.The basic rule of

brainstorming is no ideas are criticized.

Brainstorming is of three Types :

a) Freewheel

b) Round Robin

c) Card Method

In Freewheeling type of brainstorming, everybody participates in the

simultaneous discussion

In Round Robin type of brainstorming each Individual in the group is given a

chance to give his opinion

In Card type method the Individuals write their Ideas on the Card