Six Sigma 6Ϭ: Subject: Production And Quality Management

SIX SIGMA 6
SUBJECT : PRODUCTION AND QUALITY MANAGEMENT

CONTENTS
SIX SIGMA : INTORDUCTION
ROLE OF SIX SIGMA
IMPLEMENTATION OF SIX SIGMA
DMAIC Methodology
DMADV Methodology
SIPOC Methodology
BENEFITS OF SIX SIGMA

Customer
Delight
Growing Retaining
Overseas People
Markets
Structuring Current
Manufacturing
for Leadership Cycle Time
Flexibility Challenges
Responding Keeping up
More with
Quickly Technology
Advances
Reducing
Costs
SIX SIGMA: INTRODUCTION
Business Improvement Approach

Focus of Six Sigma1
Reducing variability in key product quality characteristics to
the level at which failure or defects are extremely unlikely
Tasks through 6 achieved in corporate business1:
Improving quality critical for customers
Reducing costs
Objectives of Six Sigma program: Enhanced product

quality, yield and cost all of which, in turn, improve
customer satisfaction2
SIX SIGMA
Six Sigma is a set of process improvement techniques and tools

in statistical quality control, mainly applied to make customer
happier and increase profits
The term Sigma () refers to measure of variation.
N DPMO* YIELD
1 691462 30.8538
2 308538 69.1462
3 66807 93.3193
4 6210 99.3790
5 233 99.9767
6 3.4 99.9997
* Defects per Million Oppurtunity
SIX SIGMA: HISTORY
Dr Mikel J Harry wrote a paper relating early failures to Quality in
1986
Bill Smith introduced it at his workplace while working as an engineer

at Motorola,USA in 1986
Jack Welch made it central to his business strategy at

General Electric,USA in 1995 and made the concept was popularized
Mumbai Dabbawala
That's too with limited resources

Criterias for Applying Six Sigma
Project Impact on the bottom line : $ Profit

Justification to the Quality Gained
Applications Does it need the SIX SIGMA ?
GE Six Sigma Economics
6 Sigma Projest Success
$2,500
$2,000
$1,500
Cost
Benefit
$1,000
$500
$0
1996 1998 2000 2002
ROLE OF SIX SIGMA
OBJECTIVES OF 6 :
Improve customer satisfaction
Improve quality of product and service
Reduce process cycle time
Overall cost saving
Development of Staff Skill
Eliminating Waste or Defects
WHERE 6 IS USED
Manufacturing and service industries
Sales and marketing
Accounting and financing
IMPLEMENTATION OF SIX SIGMA
Six Sigma Methodology inspired by Deming's Plan-Do-Check-Act Cycle
DMAIC DMADV
SIPOC
DMAIC
STEPS DEFINITION TOOLS USED
Define Define the problem or project goal that FMEA

needs to be addressed Process Flow Chart
Value Added Flow Chart
Measure Measure the current performance in various MSA
aspects. It is a data collection step SPC
Histogram and Pareto Chart
Analysis Analyse the process to determine root causes DoE
of variation, poor performance(defects) Why-5
Cause and Effect Diagram
Improve Improve process performance by addressing 5S
and eliminating the root causes TPM
Kaizen
Control Control improved process and future process Control Plan
performance Standardized Work
Check Sheet
SPC
DMADV
STEPS DEFINITION
Define Define design goals that are consistent with customer demands and
the enterprise strategy
Measure Measure and identify CTQs (characteristics that are Critical To
Quality), measure product capabilities, production process capability,
and measure risks.
Analysis Analyze to develop and design alternatives
Define Design an improved alternative, best suited per analysis in the

previous step
Verify Verify the design, set up pilot runs, implement the production process
and hand it over to the process owner(s)
The DMADV methodology, instead of the DMAIC methodology, should be used when:
A product or process is not in existence at your company and one needs to be
developed
The existing product or process exists and has been optimized but still does not
meet the level of customer specification or Six Sigma level
SIPOC
SIPOC is a high-level view of a process
Lean Six Sigma Approach
SIX SIGMA: BENEFITS
Enhanced ability to provide value to customer
Enhanced understanding of business processes
Reduction of Waste
Improved profit performance
Make customer happier
Summary
Dr. W. Edwards Deming proposed to eliminate slogans and
programs to improve quality, rather he advised to work to
improve the system and provide information on that.1
Six Sigma is the improvement process in which various
techniques and tools are used to decrease variability in
production and increase profit with statistical quality control,
DMAIC and DMADV are six sigma implementation
methodologies inspired by Sir Demings Plan-Do-Check-Act
cycle
Questions
Explain Six Sigma and its objectives ?
Enlist Six Sigma methodologies and explain DMAIC ?
References
1. Douglas C. Montgomery, Introduction To Statistical Quality Control, John
Wiley & Sons, Fourth Edition, Pg. 23
2. Mikel J. Harry, The Nature of Six Sigma Quality, Motorola Inc., 1986.

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SIX SIGMA 6

SUBJECT : PRODUCTION AND QUALITY MANAGEMENT

BENEFITS OF SIX SIGMA

Business Improvement Approach

Objectives of Six Sigma program: Enhanced product

Six Sigma is a set of process improvement techniques and tools

Bill Smith introduced it at his workplace while working as an engineer

Jack Welch made it central to his business strategy at

That's too with limited resources

Project Impact on the bottom line : $ Profit

Define Define the problem or project goal that FMEA

Define Design an improved alternative, best suited per analysis in the

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