CME347 – LEAN

MANUFACTURING
UNIT I – BASICS OF SIX SIGMA

M. Vinoth Kumar
Assistant Professor/ Mechanical
Mount Zion College of
Engg. & Tech.,
MZCET-MECH-V SEM-CME347-U
NIT1
 Course outcome
• At the end of this unit the students would be
able to discuss the basics of 6 Sigma

MZCET-MECH-V SEM-CME347-U
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 BASICS OF 6 SIGMA
• 1.1 Introduction to 6 Sigma
• 1.2 Basic tools of Six Sigma like Problem
solving approach
• 1.3 Standard Deviation
• 1.4 Normal Distribution
• 1.5 Various six sigma levels with some
examples
• 1.6 Value for the enterprise
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 BASICS OF 6 SIGMA
• 1.7 Variation and sources of variation
• 1.8 Mean and moving the mean
• 1.9 Various quality costs and cost of poor
quality

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 Previous Class
 1.3 Standard Deviation
 1.4 Normal Distribution

Today’s Session
 1.5 Various sigma levels with
some examples

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DPMO
• Defects per million opportunities is the actual,
observed number of defects, extrapolated to
every 1,000,000 opportunities.
• This is different from “defective parts per
million” (defective PPM), because one “Part”
may have multiple “Opportunities” to be
defective.
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As an example: let's say you manufacture 1cm ball

bearings, and you measure for:
• Diameter must be correct within 0.01%
• Weight must be correct within 0.01%
• Roundness must be correct within 0.01%
• Hardness: must resist permanent deformity due
to slow crushing by a specific testing machine
• So each part has 4 opportunities to be
defective.
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Importance of DPPM and DPMO

• Both defective PPM and DPMO are indicators
for the effectiveness of a process.
• The use of DPMO helps in making the decision
of “which process is most in need of
improvement.
• This is important because no organization has
sufficient resources to improve everything
immediately.
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METRICS USED TO EVALUATE
DEFECTS
• DPU (Defects Per Unit)
• DPO (Defects Per Opportunity)
• DPMO (Defects per Million Opportunities)
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DPMO
• Defects-Per- Million-Opportunities, which is abbreviated as
DPMO. It is also called NPMO or Nonconformities per Million
Opportunities.
• It is defined as the ratio of the number of defects in a sample
to the total number of defect opportunities multiplied by 1
million.
• DPMO is a long-term measure of process performance.
• It is a measure of the error rate of a process.
• The metric tells you how good your process is towards
committing mistakes.
• It requires you to think reversely.
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Example
Mr. X has got the business of printing
visiting cards. Each order is considered as a unit.
Each order has four defect opportunities i.e.
incorrect, typo, damaged or incomplete. Fifty
orders have been randomly selected and
inspected. Out of the fifty orders, six orders have
a problem, and there are a total of seven defects
out of fifty orders that have been sampled.
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The conclusion is: that your process will

generate 35,000 opportunities for committing
defects or errors when it has produced 1 million
orders.
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DPMO CALCULATION:
EXAMPLES
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Exercise Problem: 1
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SOLUTION:
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Summary
• Various Sigma Levels with some examples

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Other References

• Quality Planning and Analysis – JM Juran &

amp; FM Gryna. Tata Mc Graw Hill
• The Toyota Way: 14 Management Principles
• Gemba Kaizen: A Commonsense Approach to
a continuous improvement strategy, Masaki
Imai

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