六西格玛管理的概念与应用

,- office,6s,Well, 6 Sigma,概念與應用,何謂 6-Sigma ?, 1979 年 ，當時 Motorola一位資深業務主管 Arthur Sundry 在高階主管會議上說：Our quality levels really stink !, Six Sigma Quality Program 此名稱乃為 Motorola工程師 Bill Smith所建議，為Robert Galvin所採納。, 1987年，Motorola提出企業品質目標：,1989,之前改善10倍,1991之前改善100倍,1992之前達成 6-Sigma 水準, 1988年 Motorola榮獲第一屆美國國家品質獎 MBNQA, USA Today 以Top Quality is Behind Comeback為標題報導。, 1992提出,Six Sigma and Beyond：,所做的每一件事不但要達到 Six Sigma，並且超越它。,尺標從 ppm(parts per million)到 ppb(parts per billion),往後每兩年再降低瑕疵率10倍。,美國某顧問機構調查 企業急需改善 之 10 大需求:,1. 市場佔有率/成長,2. 全球市場擴張,3. 供應鏈管理,4. 設施合理化與效率化運用,5.降低製造成本,6.資產管理,7.通路領導性,8.股東價值,9.產品線合理性,10.Raw material volatility,Benefits,約 2.5 : 1 且成長中,改善服務水準,加速回應速度,在GE顧客端之專案:,- 增進業務營收,- 生產邊際效應增加,奇異公司推行6-Sigma之成本與效益,Statistics Meaning of 6 Sigma,Whats the meaning of Sigma,How to measure the data ? Which one is better ?,100, 90, 110, 120, 80, Mean = 100,100, 110,110, 90, 90, Mean = 100,平均值,變異數,標準差,從群體,N,中取樣,n,樣本,平均值,樣本,變異數,樣本,標準差,Measurement System,A Graphic/Quantitative Perspective on Variation,Average Value,Many Data Sets Have a Normal or Bell Shape,Number of,People,Arriving,at CRD,Time,7:00,7:15,7:30,7:45,8:00,8:15,8:30,8:45,9:00,9:15,Z,- Scale of Measure,Z,=,A Unit of Measure Equivalent,to the Number of,Standard,Deviations,that a Value is Away,from the,Target Value,-3.0,-0.5,3.0,Z - Values,USL,LSL,2.5,0.5,3.0,= Process Mean,Z,T,Target,0,A 3,Process,區間,區間內,所,所佔百,分,分比,1,2,3,4,5,6,依據,z,table,常,常態,分,分配區,間,間內所,佔,佔百分,比,比的數,字,字：,68.27%,99.73% (27000ppm),99.9999998 %(2ppm),99.9937%(6300ppm),99.999943%(57 ppm),95.45%,Problem SolvingApproach,Center,Process,Reduce,Spread,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,Off-Target,Unpredictable,On-Target,6,HelpsusIdentifyandReduce,VARIATION,dueto:,- InsufficientProcess Capability,- Unstable Parts &Materials,- InadequateDesign Margin,Target,USL,LSL,Target,USL,LSL,Target,USL,LSL,Center,Process,Reduce,Spread,Off-Target,Unpredictable,On-Target,Defects,Problem SolvingApproach,“LowerSpecificationLimit”,“UpperSpecificationLimit”,Less VariationMeans,FewerDefects,&,HigherProcessYields,6,有多小?,Sigma,PPM,0.002,0.5742,63.37,2,700,45,500,317,310,面積,一般教,室,室,2,倍,約,6,甲地,約,30,個中正,紀,紀念堂,略大於,台,台北市,台北縣,的,的兩倍,半,半,台灣省,的,的面積,時間,1,秒鐘,4.8,分鐘,9,小時,半個月,約,9,個月,5,年,6,的四個,假,假設,常態分,配,配,1.5,偏移,和,已知,缺點乃,隨,隨意分,佈,佈，且,不,不同零,件,件及製,程,程相互,獨,獨立,偏移1.5,在動態,的,的真實,世,世界中,，,，每一,件,件事都,在,在不停,的,的變化,著,著,溫度,溼度,工具的,磨,磨耗,原料的,差,差異.,1.5,乃由機,率,率、估,計,計、經,驗,驗而來,參考資,料,料:,Evans,D.H.(1975):StatisticalTolerancing: TheStateoftheArt,Part III.Shifts andDrifts.,4.5,6,的品質,水,水準,0.002ppm,C,p,=2,中心值,1.5,的偏移,3.4ppm,C,pk,=1.5,或用,npmo (nonconformitiesper millionopportunities),表示,SigmaDPMOYieldSigmaDPMOYield,6,5.9,5.8,5.7,5.6,5.5,5.4,5.3,5.2,5.1,5.0,4.9,4.8,4.7,4.6,4.5,4.4,4.3,4.2,4.1,4.0,3.9,3.8,3.7,3.6,3.5,3.4,3.3,3.2,3.1,3.0,2.9,2.8,2.7,2.6,2.5,2.4,2.3,2.2,2.1,2.0,1.9,1.8,1.7,1.6,1.5,1.4,1.3,1.2,1.1,1.0,0.9,0.8,0.7,0.6,0.5,0.4,0.3,0.2,0.1,3.4,5.4,8.5,13,21,32,48,72,108,159,233,337,483,687,968,1,350,1,866,2,555,3,467,4,661,6,210,8,198,10,724,13,903,17,864,22,750,28,716,35,930,44,565,66,807,99.99966%,99.99946%99.99915% 99.99866%99.9979%99.9968%99.9952%99.9928%99.9892%99.984% 99.977%99.966%99.952% 99.931%99.90% 99.87%99.81%99.74% 99.65%99.53%,99.38%,99.18%98.9%,98.6%,98.2%,97.7%,97.1%,96.4%,95.5%,94.5%,66,807,80,757,96.801,115,070,135,666,158,655,184,060,211,855,241,964,274,253,308,538,344,578,382,089,420,740,460,172,500,000,539,828,579,260,617,911,655,422,691,462,725,747,758,036,788,145,815,940,841,345,864,334,884,930,903,199,919,243,93.3%,91.9%,90.3%,88.5%,86.4%,84.1%,81.6%,78.8%,75.8%,72.6%,69.1%,65.5%,61.8%,57.9%,54.0%,50.0%,46.0%,42.1%,38.2%,34.5%,30.9%,27.4%,24.2%,21.2%,18.4%,15.9%,13.6%,11.5%,9.7%,8.1%,SigmaVS.DPMO,衡量指,標,標,標竿研,究,究,願景,Philosophy,方法,工具,符號,目標,價值,s,2,3,4,5,6,308,537,66,807,6,210,233,3.4,.,s,DPMO,可用以,計,計算與,衡,衡量任,何,何流程,Sigma,之,之另一,稱,稱呼為,標,標準差,2000,年達成6-Sigma水,準,準,4,1996 -Jack Welch,變成我,們,們文化,的,的一部,份,份 - 成,為,為我們,生,生活的,一,一部份.,6 Sigma OrganizationinGE,Structure,Quality Council,Members: Labs & Functions,“Pipeline” & BB Project Priorities,Training & Certification,Measurements & Rewards,Communications,Champions,Leadership: Overall Initiative,Project Funding,HR: Training & Rewards,Black Belts,Lead 6,Project Teams,“Measure/Analyze”,“Improve/Control”,Out with Businesses,Here at CRD,Master Black Belts,Teach 6,Mentor Black Belts,Monitor BB Projects,Work “Pipeline” Projects,A Resource Pool,Team Members,Learn/Use 6,Tools,Work on BB Projects,Part of The Job,Out with Businesses,DMAIC,訓,訓練,綠帶(GreenBelt),(專案,組,組組長),黑帶(BlackBelt),(專案,組,組組長),碩士黑,帶,帶(MBB),(,教練/,資,資源供,應,應者),10,天,天3,週,週課堂,訓,訓練,24,週,週課堂,訓,訓練,35,週,週課堂,訓,訓練,補強訓,練,練 :,專案/workplace,咨詢協,助,助與教,導,導,- 問,題,題解決,與,與改善,工,工具,- Facilitation,與,與團隊,運,運作,等等,- 問,題,題解決,與,與改善,工,工具,- Facilitation,與,與團隊,運,運作,- 基,本,本統計,- 高,等,等/進,階,階統計,- 問,題,題解決,與,與改善,工,工具,- Facilitation,與,與團隊,運,運作,- 基,本,本統計,等,等等,補強訓,練,練 :,專案/workplace,咨詢協,助,助與教,導,導,補強訓,練,練 :,專案/workplace,咨詢協,助,助與教,導,導,扮 演,角,角,色,色,綠帶/,黑,黑帶(GB/BB),碩士黑,帶,帶(MBB),負專案,全,全責-,黑,黑帶(,專,專職)/,綠帶(,兼,兼職),專注於1-2,專,專案小,組,組,依專案,特,特性挑,選,選出,流程盟,主,主,(ProcessChampion),專職之,職,職位,協助多,個,個專案,小,小組,開發導,入,入專家,資,資源,管理之,責,責任,專注於,一,一個關,鍵,鍵流程,或,或次流,程,程,被BUBPS委員,會,會依流,程,程性,質而選出,專案小組,領,領導技巧,專案管理,技,技巧,問題分析,與,與解決技,巧,巧,跨功能工,作,作經驗,分析/技,巧,巧專長,流程之指,導,導/監督/教育技,能,能,負責流程,功,功能/目,標,標達成/,維,維持,關鍵項目,之,之管制/,主,主導定期,流,流,程審查,負責跨功,能,能介面問,題,題與議題,之解決,跨功能認,識,識與了解,溝通/談,判,判技巧,原因分析,技,技能,專案小組,領,領導技巧,負責專案,進,進度/小,組,組工作計,劃,劃,並將之與,管,管理層級,聯,聯接,開發衡量,與,與管制系,統,統 (如, 資,料蒐集計,劃,劃/流程,管,管制表等),開發BB/帶動專,案,案小組成,功,功,/,提供流程,改,改善與統,計,計技巧的,專長,亦可能被,指,指派加入,流,流程管理,小組,專,長,職,責,敘,述,6,品質方案,的,的架構,Total Customer Satisfaction,縮短作業,週,週期,參與式管,理,理,Empowerment,標竿研究,.,.,6,QualityProgram, Cp, Cpk, Dpu,QUALITY METRICS,IMPROVEMENT PROCESS,Identifyproductorservices,Identifycustomer requirements,Identifyyour needs,Define the process,Mistake-proof the process and eliminatewasted effort,Ensure continuous improvement,TOOLS FOR SIX SIGMA,Design to standard parts/materials,Design to standard processes,Design for assembly,Partstandardization,SupplierSPC,Processstandardization,Statisticalprocesscontrol.and more,DMAIC,DFSS,推行 6-Sigma 之,必,必要條件,重點攻擊,與變格管,理,理相聯接,依核心流,程,程(非功,能,能) 組,織,織 黑帶,或,或碩士級,黑,黑帶,UseRelevantExamples Your Business,Your Language,追求即早,勝,勝利 (,大,大且易見),支持基礎,結,結構/追,溯,溯系統,改變衡量,系,系統以更,有,有效drive專,案,案行動,選擇與工,作,作直接相,關,關專案,高層,參與-,克,克服障礙,品質改善,的,的流程,1. 定,義,義產品或,服,服務,2. 鑑,定,定顧客及,其,其需求,3. 列,出,出滿足顧,客,客需求所,需,需之條件,4. 定,義,義(規劃)流程,5. 防,範,範流程錯,誤,誤並消除,浪,浪費,6. 確,保,保持續改,善,善,5 階段,問,問題分析,解,解決流程(DMAIC),提高目標,另一,主題,第一階段,第,第二階,段,段,第,第三階,段,段,第,第四,階,階段,第,第,五,五階段,24,管 制,(Control),改 善,(Improve),分 析,(Analyze),衡 量,(Measure),定 義,(Define),選擇專,案,案,成立專,案,案小組,確認CTQs,Y,定義衡,量,量指標,($ ?),衡量系,統,統驗證,定義不,良,良,基準線,設定目,標,標,確認X,重點少,數,數 xs,效果測,試,試,(Pilot Soln),Y =f(x),確認效,果,果,持續性,HowDo We ArriveatSigma?,Measuring &EliminatingDefectsis the “Core,”,” ofSixSigma,IdentifytheCTQs,LookforDefects,inProductsor,Services,“Critical toQuality,”,”,Characteristicsor,theCustomer,Requirementsfora,Productor Service,CountDefects,or failuresto,meetCTQ,requirementsin,allprocesssteps,DefineDefect,Opportunities,Anystepinthe,processwhere a,Defectcould occur,in aCTQ,Arrive atDPMO,UsetheSIGMA,TABLE,ConvertDPMOto,Sigma,Defects PerMillion,Opportunities,2,3,4,5,6,308,537,66,807,6,210,233,3.4,PPM,Defects per,Million of,Opportunity,Sigma,Level,谢谢观,看,看,/,欢迎下,载,载,BYFAITHI MEANAVISIONOFGOODONECHERISHES ANDTHEENTHUSIASMTHAT PUSHESONETOSEEKITSFULFILLMENTREGARDLESSOFOBSTACLES. 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