西格玛介绍资料课件

Introduction of Six SigmaBelton GroupRex WongRex Wong噪峡僚硅鲸晌望苗遍涨姑睬俱罐釜墒这封月谦唤移伪泊铬奋巧从兔宙蹲坪6西格玛介绍6西格玛介绍Introduction of Six SigmaBelto1 1Scope of Module What is Six Sigma Why the need for Six Sigma How to apply Six Sigma脸匹侮厌讽跌倪杀桑辆轧蚁寝钟筐肘呜罩娶潦残灵及宝碗喘捣舅涧芦薪焕6西格玛介绍6西格玛介绍2 2Scope of ModuleWhat is Six Sig2 2What is Six Sigma?Six SigmaSix Sigma is a comprehensive and flexible is a comprehensive and flexible system for achieving,sustaining and maximizing system for achieving,sustaining and maximizing business success.It is uniquely driven by close business success.It is uniquely driven by close understanding of customer needs,disciplined understanding of customer needs,disciplined use of facts,data and statistical analysis,with use of facts,data and statistical analysis,with diligent attention to managing,improving and diligent attention to managing,improving and reinventing business processes.reinventing business processes.Peter S Pande,Robert P Neuman,Roland R CavanaghPeter S Pande,Robert P Neuman,Roland R CavanaghThe Six Sigma WayThe Six Sigma Way(McGraw Hill,2000)(McGraw Hill,2000)疑拂抬欺渠呵譬啡肾匈皖叛瓜乖瓶辱斧泽转竭刮女柞臃婴闽免牵舆说癣补6西格玛介绍6西格玛介绍3 3What is Six Sigma?Six Sigma is3 3Six Sigma Is Three ThingsA statistical measurementA business strategyA philosophy课甘毒裂飘靖黄募叁恃唁盒聂捉垃训阑蜗吞仓塞搅嚼臀灯蕊皆肋糕曰棘乘6西格玛介绍6西格玛介绍4 4Six Sigma Is Three ThingsA sta4 41)Six Sigma A Statistical Measurement It provides a quantitative performance assessment of It provides a quantitative performance assessment of our products,services and processes.our products,services and processes.It allows for comparisons against other similar or It allows for comparisons against other similar or dissimilar products,services and processes.dissimilar products,services and processes.It provides feedback on how far ahead or behind we are.It provides feedback on how far ahead or behind we are.Six Sigma helps to establish our course and to gauge our pace in the race for total customer satisfaction.籍选桑女冤泽亏恫笛叮摸因耀护烹何音安逆熏彝愿捎患佩奠乍挚蝴笛托黔6西格玛介绍6西格玛介绍5 51)Six Sigma A Statistical5 5Six Sigma A business strategyImproved Sigma-Rating of ProcessImproved Product or Process QualityReduced Cost of OperationsGreater Customer Satisfaction讶跋札似圣盯槽咐妖捻伤烹这杂壤玖雨赖碾空辨吊曾狠挽髓瓣门拥拼伯侠6西格玛介绍6西格玛介绍6 6Six Sigma A business strateg6 6Cost Of Poor Quality(COPQ)Traditional Quality Costs(tangible)Lost OpportunityHidden FactoryAdditional Costs of Poor Quality(intangible)(Difficult or impossible to measure)COPQ is a function of Sigma Capability InspectionWarrantyScrapReworkRejectsMore SetupsExpediting CostsLost salesLate DeliveryLost Customer LoyaltyExcess InventoryLong Cycle-TimesEngineering Change Orders祟导浮肖曲析驾誉梁想哨姜虎郊共闽侦抚消伶宗鼎白哺秸坞健甩盲撞恃掀6西格玛介绍6西格玛介绍7 7Cost Of Poor Quality(COPQ)Tra7 7Cost Of Poor Quality(COPQ)ProfitTotal Cost to Manufactureand DeliverProductsProfitTheoreticalCostsCost ofPoor QualityCOPQPrice ErosionTheoreticalCostsCost ofPoor QualityCOPQProfitTheoreticalCostsCOPQ买盅李肝薛玄粱炽吱轴菱迄疮氰侄餐议钳日研净只封鹊旨关努族虎拦故馁6西格玛介绍6西格玛介绍8 8Cost Of Poor Quality(COPQ)Pro8 83)Six Sigma A philosophy Six Sigma is about working smarter,not harder.Six Sigma is about working smarter,not harder.Discover and neutralize harmful sources of Discover and neutralize harmful sources of variationvariation MMistakes are reduced(or eliminated)istakes are reduced(or eliminated)Improved process capabilityImproved process capability Sigma rating goes upSigma rating goes up拙滇所撑和疆图颓琶朽姿真巷屹吨忽温或气泞否建巷薄湖腆绅妊壳羽澄贯6西格玛介绍6西格玛介绍9 93)Six Sigma A philosophySix9 9Quality BreakthroughTimeReject RateHistorical Level(0)Natural Variation under 0(30)Special VariationOptimum Level(1)Natural Variation under 1(31)溉磕绑亿央颅雕整橡桨夷瑚烷茂贬浙容颐罗捌氮拆疚居馒狈锭佯堤啥库黔6西格玛介绍6西格玛介绍1010Quality BreakthroughTimeReject1010Why needs of Six Sigma?The goal of The goal of Six SigmaSix Sigma is not to achieve six sigma is not to achieve six sigma levels of quality(i.e.3.4 dpmo).levels of quality(i.e.3.4 dpmo).Six Sigma is about improving profitability;improved quality and efficiency are immediate by-products.诣南自漠养拌既聘砾霜赦圃孝羹伴笆镊鬃烛鹏刘慷抱腻耘刑巴帽更它拘掸6西格玛介绍6西格玛介绍1111Why needs of Six Sigma?The goa1111Six Sigma aggressive goalSigma is a statistical unit of measure that reflects process capability.The sigma scale of measure is perfectly correlated to such characteristics as defects-per-unit,parts-per million defective,and the probability of a failure/error.PPMProcessCapabilityDefects per Million Opp.哦小夯匣择黎耸矾摩斌准砚事腮暑捆活寄博蔷渊翁啃椭冶蛔邢驳开锦蜀醛6西格玛介绍6西格玛介绍1212Six Sigma aggressive goalSig1212Six Sigma Process Point of Inflection1 TUSLp(d)12345633 This is a 6 Sigma Process亮麦殿成落嘱琶籍趣参硼闺唯蛀歪搔逻堡彬隶绸椽女剩铣卉檄咆脆触熏岁6西格玛介绍6西格玛介绍1313Six Sigma ProcessmPoint of Inf1313Benefit of Six Sigma Cost reductionCost reduction Productivity improvementProductivity improvement Market-share growthMarket-share growth Customer retentionCustomer retention Cycle-time reductionCycle-time reduction Defect reductionDefect reduction Culture changeCulture change Product/service developmentProduct/service development宰蛊六涸快随豢苗孟驰衷隶另馈分坯峡继熏畸春渤乡殷馒民佬茨挡周藕绢6西格玛介绍6西格玛介绍1414Benefit of Six SigmaCost reduc1414Customers Needs Internal MetricsDeliveryPriceQualityCustomerSupplierNeedCycle TimeCostDefectsDo虹贮埃悦脯尼酶亨昭鸥赤暮给睫掇鲤苑预硝沂蔼杉灼郁越耍瞳唾横桐斯刚6西格玛介绍6西格玛介绍1515Customers Needs Internal 1515How to apply Six Sigma?Unlike conventional improvement programs which Unlike conventional improvement programs which focuses on improving the defects on the“output”,focuses on improving the defects on the“output”,Six Six SigmaSigma focuses on the“process”that creates or focuses on the“process”that creates or eliminates the defects.eliminates the defects.Six Sigma Six Sigma seeks to reduce variability in a process by seeks to reduce variability in a process by means of a systematic approach called the means of a systematic approach called the Breakthrough Breakthrough StrategyStrategy.ProcessProcessInputInputOutputOutput剔畏降婴狮过贝浑笔婉制挫每溪堕丸萤抢赊柒擂具溢皮历补拿冉泣汀陵郁6西格玛介绍6西格玛介绍1616How to apply Six Sigma?Unlike 1616Six Sigma approachIdentify the Customers NeedCenter around the TargetReduce VariationReduce Defects酵躇萨得婴两笔真捂舜涛寡眉相栽很衔计售廖锈课战韩炳衡赤否棺驴锻吕6西格玛介绍6西格玛介绍1717Six Sigma approachIdentify the1717Focus of Six Sigma?ProcessProcessInputInputOutputOutputThe output(Y)is perceived as a function of the input(X).响恼从超即愧寸潜编肾恢奴煌定丢嚼攻汰香孜原眶喊臀缀晃言钡呵恨俊值6西格玛介绍6西格玛介绍1818Focus of Six Sigma?ProcessInpu1818Breakthrough Strategy 缨夕碧烤谁桩愤循锑丑叙冕跋幽吕钓钒俺酷烈育秀朋柏骗浙渊坤签舱洽依6西格玛介绍6西格玛介绍1919Breakthrough Strategy Breakthr1919Define The The DefineDefine phase sets the stage for a successful phase sets the stage for a successful Six Six SigmaSigma project by addressing the following questions:project by addressing the following questions:What is the problem of our focus?Whats our goal?And by when?Whos the customer impacted?What are the CTXs in-concern?Whats the process under investigation?癌祝受亭怪钻标惮禄锌廊蔼忘冉审阵刺趟轧争眶吕池诅著臣赣兆丑会笆烂6西格玛介绍6西格玛介绍2020DefineThe Define phase sets th2020Project Definition Improve time to market for all productsImprove time to market for all products Lead the industry in key technologiesLead the industry in key technologies Create world-class manufacturing processesCreate world-class manufacturing processes Develop strategic supplier relationshipsDevelop strategic supplier relationships Provide best-in-class product and process qualityProvide best-in-class product and process quality Develop strategic relationships with key customersDevelop strategic relationships with key customers Become an employer of choiceBecome an employer of choice涩套册竿掘找诌隘钻解陷首怒荆谭怔漏帖悠毯疼樟惹热椰滩充驱卢铲汲潍6西格玛介绍6西格玛介绍2121Project DefinitionImprove time2121Baseline Metric Data BaselineBaseline The average long-term defect The average long-term defect level of a process when all input variables in level of a process when all input variables in the process are running in an unconstrained the process are running in an unconstrained fashion.fashion.EntitlementEntitlementThe best-case short-The best-case short-term defect level of a process when all input term defect level of a process when all input variables in the process are centered and in-variables in the process are centered and in-control.control.BenchmarkBenchmarkThe defect level of the The defect level of the process deemed by comparison to be the process deemed by comparison to be the best process possible.best process possible.拯豺芝鹤敞庄叹脂涅顿沛溢腻蔫疥中翌儡炬蚂熏场颓寒而烂悲浅唇痉判咕6西格玛介绍6西格玛介绍2222Baseline Metric DataBaselineT2222Breakthrough ImprovementTimeReject RateBaseline NID(0,0)Natural Variation(30)Special VariationGoal NID(1,1)Natural Variation(31)EntitlementOpportunity for Improvement()0.7滴俭岳侮寐颓沈蔼旅热咀裸勾摩康豪娱痈磁鬼遁俞腊品还媳皂衷柏舍秀抗6西格玛介绍6西格玛介绍2323Breakthrough ImprovementTimeRe2323Cost of QualityHard Savings Potential Savings Soft Savings城捏族爪店轰穗花驶犀俩璃锌寡卧八痕恰舌盒哄爆品业辉庇蘸瑶炙厕磐甲6西格玛介绍6西格玛介绍2424Cost of QualityHard Savings 2424Measurel lThe Measure phase serves to validate or refine the problem,and to begin the search for root causes.It addressesthe focus and extent of the problem,based on measures of the process,the key data required to narrow the problem to its major factors or vital few root causes.响搂芳笼焙毅簿呢垄复耐凝县背荣诅捞界侮啊触倪垃辙胀费邯簿晃嘿悍旧6西格玛介绍6西格玛介绍2525MeasureThe Measure phase serve2525Capability Analysis Conventional Metrics Reject RateReject Rate in in percentpercent(e.g.7.4%)(e.g.7.4%)in in ratioratio(e.g.0.074)(e.g.0.074)in in parts per millionparts per million(e.g.74,000 DPPM)(e.g.74,000 DPPM)YieldYield in in first-time yieldfirst-time yield in in final yieldfinal yield沪回卒嗅壮惩竹凄誓函捞啪溃禄娜汪栓韭崖吮上磨柏绞再拄执邦劈氟挥蹲6西格玛介绍6西格玛介绍2626Capability Analysis Conven2626Capability AnalysisCapability AnalysisCapability AnalysisConventional MetricsConventional MetricsSix Sigma MetricsSix Sigma MetricsReject rateReject rateIn precentIn precent(eg,7.4%)(eg,7.4%)In defects per Unit(DPU)In defects per Unit(DPU)In RatioIn Ratio(eg,.074)(eg,.074)In defects per million opportunities(DPMO)In defects per million opportunities(DPMO)In parts per million In parts per million(eg,74,000 dppm)(eg,74,000 dppm)In throughput yieldIn throughput yieldYieldYieldIn first-time yieldIn first-time yieldIn rolled throughput yieldIn rolled throughput yieldIn final yieldIn final yieldIn normalized yieldIn normalized yield鲁萧玫鸭拴啮治豁耍决埋晕苍疡朵荧鉴琼兴帚无敷酞谣嗣汗豆促唤养奎迭6西格玛介绍6西格玛介绍2727Capability AnalysisCapability 2727Defect per unit(DPU)Defects Per UnitDefects Per Unit:The average number of defects per :The average number of defects per unit produced.unit produced.Defect Rate =#Defects/#Units =7/5 =1.4 dpu钙洽油岸厕俄胜销岁缝鳞乍妖判嗓缄牡式鸟冻茎费醇崭捏官峡咆乱扶昭扦6西格玛介绍6西格玛介绍2828Defect per unit(DPU)Defects P2828Defects Per Million Opportunities(DPMO)OpportunitiesOpportunities:The number of possibilities for defect creation in :The number of possibilities for defect creation in any unit of product process or sequence of processes.any unit of product process or sequence of processes.1.Arm Height2.Arm thickness3.Bore hole Dia4.Swgae hole Dia5.Roughness6.Teardrop profile7.Roll8.PitchOpportunities per Unit =8Number of Opportunities=Opportunities per Unit Number of Units=8 5 =40Defect Rate=#Defects/#Opportunities =(7/40)106=175,000 dpmo矫凰就令升疗廊钟不足箱撞帅隐矢吼怜峰巴鹰寥猪蝇钉妻疫硼观开谓仁赌6西格玛介绍6西格玛介绍2929Defects Per Million Opportunit2929DPMO vs Sigma Capability 唾蘸苟抛励济捅颊禹痢控假哉觉讨窿贺臣扶侠岛嘿朋哟洗理鞍赚涣踞臆绎6西格玛介绍6西格玛介绍3030DPMO vs Sigma Capability 唾蘸苟抛励3030First-time yield(Yft)First-Time YieldFirst-Time Yield is the number of units that pass a is the number of units that pass a particular inspection,compared with the total number particular inspection,compared with the total number of units that pass through that point in the process.of units that pass through that point in the process.Process968Accept32RejectFirst-Time Yield,Yft =968/1000 =0.9681,000Input目串尝傀癌蝇姐玻水葱囤蜘鳃邦奴孪廊车五撮星哮获献豢板穆属剑暖霸瘤6西格玛介绍6西格玛介绍3131First-time yield(Yft)First-Ti3131Throughput yield(Ytp)Throughput YieldThroughput Yield is the probability that a unit of product or is the probability that a unit of product or service will pass through a given process step error-free.service will pass through a given process step error-free.Throughput Yield,YThroughput Yield,Ytptp =e =eDPUDPUProcess968Accept32Reject1,000Input(40 Defects)Throughput Yield,Ytp =e-(40/1000)=0.961饶眺瑞葫绷绥啸戌度诺存抓痛益氟秃拄荐凋稚钵吮树步龟渍岸恤擂镀仔桐6西格玛介绍6西格玛介绍3232Throughput yield(Ytp)Throughp3232Final Yield(Yf)800ShipProcess A1,000Input50ScrapProcess B950Input25ScrapProcess C925Input125ScrapFinal Yield,Yf=Quantity Shipped/Quantity Built=800/1,000 =0.80A shortcoming of final yield is that it fails to consider the“hidden factory”or rework.Hidden Factory:ad hoc systems and processes set up to correct errors made during the mainstream process.乔哮汪然芦钉察匡抵那织烘橙南陶乱钾枪淡评枫吊查掩焕呵袄凳单丫揩酋6西格玛介绍6西格玛介绍3333Final Yield(Yf)800ShipProcess3333Rolled Throughput Yield(Yrp)Rolled Throughput Yield=Ytp(A)Ytp(B)Ytp(C)=0.7408 0.6393 0.5824=0.2758675ShipProcess A1,000Input50ScrapRework200150Process B800Input(950)25ScrapRework300275Process C650Input(925)125ScrapRework250125Defects=300 Ytp(A)=e300/1,000 =0.7408Defects=425 Ytp(B)=e425/950 =0.6393Defects=500 Ytp(C)=e500/925 =0.5824Defects=300售掏脯挞装狗懊士酋该讥凝炉揣桓炸刀顾甭刊筛礼歹狸恳滔拥融存唉败顽6西格玛介绍6西格玛介绍3434Rolled Throughput Yield(Yrp)3434Rolled Throughput Yield(Yrp)The rolled throughput yield is the probability that a unit of The rolled throughput yield is the probability that a unit of product or service is able to pass through the entire product or service is able to pass through the entire process defect-free.process defect-free.It is a function of the defect rate,and hence provides a It is a function of the defect rate,and hence provides a better estimate of the amount of rework required.better estimate of the amount of rework required.Rolled throughput yield can be improved byRolled throughput yield can be improved by having higher throughput yields at each process step having higher throughput yields at each process step reducing the number of process steps reducing the number of process steps汞措吹悍忙挺赊艺涂髓潘扶绍浇嚼二倪生羡时和钻迷资姨洁蛀戈执段欲园6西格玛介绍6西格玛介绍3535Rolled Throughput Yield(Yrp)T3535Sigma ValueSigma Value(Z-Score):The sigma value is derived from the The sigma value is derived from the probability of a defect in a process and is probability of a defect in a process and is used to compare performance across products used to compare performance across products or processesor processes z-Score is most accurately determined by z-Score is most accurately determined by using the equation of z=eusing the equation of z=e(-DPU)(-DPU)出麦交存牵库彤很砾队馈嚎凳樟闻耕犊摆穗搜秤辩宛寅劳肾之卡森熙介壮6西格玛介绍6西格玛介绍3636Sigma ValueSigma Value(Z-Sco3636Analyze In the In the AnalyzeAnalyze phase,practical business problems are phase,practical business problems are turned into statistical problems.The statistical tools turned into statistical problems.The statistical tools and the order in which they are applied will depend and the order in which they are applied will depend on the problem and process,and the approach to the on the problem and process,and the approach to the problem.problem.Analyze Data/ProcessDevelop Causal HypothesisRefine or Reject HypothesisAnalyze Data/ProcessConfirm&Select Vital Few Causes早披摈汐市魔侣哩黍馏巴闭吗自卤换骑枣阿六说笆颅节熄癣膜渡听帽粘饰6西格玛介绍6西格玛介绍3737AnalyzeIn the Analyze phase,p3737Improve The The ImproveImprove phase seeks to address the following:phase seeks to address the following:What possible actions or ideas required to address the root cause of the problem,and to achieve the goal?Which of the ideas are workable potential solutions?Which solution will most likely achieve the goal with the least cost or disruption?How can the chosen solution be tested for effectiveness,and then implemented permanently傅嫩玲草料冯仑蠢哪夏竞我饰保墓拔朴付茹订安牵衙转影收篮碟慢助圣幢6西格玛介绍6西格玛介绍3838ImproveThe Improve phase seeks3838Control In the In the ControlControl phase,actions are established to ensure that the phase,actions are established to ensure that the process is monitored continuously for consistency in quality of process is monitored continuously for consistency in quality of the product or service.the product or service.Implement ongoing measures and actions to sustain improvementDefine responsibility for process ownership and managementExecute“closed-loop”management and drive towards Six Sigma勉棍掘添搞堪隋私镊堵撬臣篮诬蔚聋踩女郸汀榴锯欲哄嫁伶予扦声莫畅昌6西格玛介绍6西格玛介绍3939ControlIn the Control phase,a3939Realizationl lIn the In the RealizeRealize phase,ownership of the project is phase,ownership of the project is transferred to the finance representative,for tracking of transferred to the finance representative,for tracking of financial benefits of the project.financial benefits of the project.喝澈酚端樊枣衬渴哎极吴步研某泡月夏镣隐砰摸歧绎崭浓偿晰缸诫拎胞杂6西格玛介绍6西格玛介绍4040RealizationIn the Realize phas4040Champion Define the path for Six Sigma implementation across the Define the path for Six Sigma implementation across the organization.organization.Careful selection of high-impact projects.Careful selection of high-impact projects.Support development of“statistical thinking”.Support development of“statistical thinking”.Realize the gains by supporting Six Sigma projects through Realize the gains by supporting Six Sigma projects through allocation of resources and removal of roadblocks.allocation of resources and removal of roadblocks.Implementation of Black Belt recommendations.Implementation of Black Belt recommendations.Ensure that project opportunities are acted upon by the Ensure that project opportunities are acted upon by the organizations leadership and the finance department.organizations leadership and the finance department.Recognition of efforts and contributions by the people.Recognition of efforts and contributions by the people.乖浙主脾脑乳悼痢乒侍乞邱娥胆岂我常慕臃慧魔哦剿立饺磋继置蜘篇衔罗6西格玛介绍6西格玛介绍4141ChampionDefine the path for Si4141Black Belt Act as Act as Breakthrough StrategyBreakthrough Strategy experts and enthusiasts.experts and enthusiasts.Identify the barriers.Identify the barriers.Management of project:from planning,through Management of project:from planning,through execution,to realization.execution,to realization.Report progress to appropriate leadership levels.Report progress to appropriate leadership levels.Determine the most effective tools to apply.Determine the most effective tools to apply.Gather input from knowledgeable sources,from Gather input from knowledgeable sources,from operators to managers.operators to managers.Green Belt TrainingGreen Belt Training Monitor&provide guidance of Green Belt projects.Monitor&provide guidance of Green Belt projects.溪霜挟纯证障矫陪揩彤威港伯倦顺癣润炼瘟赋茧虾耐必岂锑谓噪应边峡砷6西格玛介绍6西格玛介绍4242Black BeltAct as Breakthrough 4242Green Belt Function as Green Belts on a part-time basis,Function as Green Belts on a part-time basis,while performing their regular operational duties.while performing their regular operational duties.Participate in Black Belt teams in the context of Participate in Black Belt teams in the context of their existing responsibilities.their existing responsibilities.Learn the Learn the Six SigmaSix Sigma methodology as it applies to methodology as it applies to a particular project.a particular project.Continue to learn and practice the Continue to learn and practice the six Sigmasix Sigma methods and tools after project completion.methods and tools after project completion.辐铀战榨杂样根醋磋诡冒壕洲解挥例盯匙秦屎赞蔚曼蛆胀皮稠唬手没址温6西格玛介绍6西格玛介绍4343Green BeltFunction as Green Be4343Six Sigma Process FlowChampionManagementEmployeesFinanceTeamBlack Belt凋喜矣紫雏燥喀引财晤茁永挺裕磁监忧池放橙盲窄铀少滔冈螟跨咨蚂鳃楞6西格玛介绍6西格玛介绍4444Six Sigma Process FlowDefineCh4444Six Sigma RoadmapOptimized Process30-5010-154-8Key Process InputVariables(KPIVs)8-10KPIVsCritical KPIVs3-6Key Leverage KPIVsInputs VariablesProcess MapMulti-Vari Studies,CorrelationsScreening DOEsDOEs,RSMC&E Matrix and FMEAGage R&R,CapabilityT-Test,ANOM,ANOVAQuality SystemsSPC,Control PlansMeasureAnalyzeImproveControl筛政止朽祭靳羚良揽假疯符绷儒蘸杏啥幂妮商艘汞仁挤鞍考薯朋颤舟骚庭6西格玛介绍6西格玛介绍4545Six Sigma RoadmapOptimized Pro4545What you have learnt?What is Six Sigma?What is Six Sigma?A statistical measurementA statistical measurement A business strategyA business strategy A philosophyA philosophy Why the needs of Six Sigma?Why the needs of Six Sigma?How to apply Six Sigma?How to apply Six Sigma?Measure,Analyze,Improve&Control(MAIC)Measure,Analyze,Improve&Control(MAIC)Six Sigma T