MINOR PROJECT PRESENTATION

ON
STUDY OF SOME ASPECTS OF SIX SIGMA
PHILOSOPHY AND METHODOLOGY
BY
RAUSHAN KUMAR
1501061
UNDER SUPERVISION OF DR. ANUPAM DAS
CONTENT:
• INTRODUCTION
• LITERATURE REVIEW
• CONROL CHART
• DMAIC&DMADV METHODOLOGY
• PROCESS CAPABILITY INDICES
• CASE STUDY
• REFERENCES
INTRODUCTION:
• A Six sigma(6σ) is a set of techniques and tools for process improvement. It
was introduced by engineer Bill Smith while working at Motorola in
1986.Jack Welch made it central to his business strategy at General Electric
in 1995.
• Six- Sigma is a statistical methodology to reduce defects up to only 3.4
defects per million opportunities. Six-Sigma is a management philosophy
focused on eliminating mistakes, waste and rework.
• Steps required for six sigma compliance process:
1. To check the preciseness of process , control charts are used
2. To check accurateness of the process , process capability analysis is done.
3. For existing products DMAIC approach is used.
4. For new product DMADV approach is used.
 LITERATURE REVIEW:
• Md. E. Kabir at all [1]. This research work has been carried out in a fan manufacturing
company to show how to improve its productivity and quality by using Six-sigma. The
objectives of this paper are to study and evaluate processes of the case organization, to
find out current sigma level and finally to improve existing sigma level through DMAIC
approach.
• Shah S. at all [2]. This paper focuses on use of control chart in pharmaceutical processes.
This paper deals about elements of control chart and types of various control charts
along with example. Advantages of various control charts are also included.
• T. Maia at all [3].This paper illustrates the process capability analysis performed for
boring operation . Application of control chart for boring operation is also illustrated . It
also consists of detailed explanation of process capability indices.
• V. Aden at all [4]. This paper presents a Six Sigma project conducted at a semiconductor
company dedicated to the manufacture of circuit cartridges for inkjet printers. This
project was conducted through DMAIC approach and hence ,it consists of a detailed
explanation of DMAIC approach and its various aspects
CONTROL CHART:
 Types of control chart:
• Attribute control chart-
These are used for product characteristics that can be evaluated with a discrete
response (such as yes/no, good/bad, pass/fail).
a. p-chart
b. np-chart
c. C-chart
d. U-chart
• Variable control chart-
It is used when measurements are quantitative (for example, height, weight, or
thickness).
a. X-bar & S-chart
b. X-bar & R-chart
DMAIC & DMADV METHODOLOGY:
DMAIC:
It is the more well-known and most-used Six Sigma project
methodology and is focused on improving an existing process, rather
than creating a new product or process.
• D — Define the problem with your product or process.
• M — Measure your current process and collect data.
• A — Analyze your data to find the root causes of defects.
• I — Improve your process based upon your data analysis and test it.
• C — Control your new process and monitor for defects. (SPC
techniques are helpful in this phase.)
DMAIC CYCLE
DMADV:
It stands for these five phases of a Lean Six Sigma project that’s aimed at
creating a new product or process design:
• D — Define process and design goals
• M — Measure (and identify) critical-to-quality aspects of your
process/product, including risks and production capabilities
• A — Analyze to develop process designs and evaluate to select the best
design for your process
• D — Design process details and optimize your design. Test your design(s)
• V — Verify the chosen design for your process with pilot-testing.
Implement and monitor the new process
PROCESS CAPABILITY INDICES:
• An important technique used to determine how well a process meets a set of
specification limits is called a process capability analysis.
• To measure process capability, there is a ratio or index being used and this is
called as the process capability index. This measures the ability of a process to
produce a certain output within the limits specified.
Cp: It is known as potential capability of a process. It simply relates the
Process Capability to the Specification Range and it does not relate the
location of the process with respect to the specifications.
𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐𝑎𝑡𝑖𝑜𝑛 𝑤𝑖𝑑𝑡ℎ
Cp = , Cp = (USL – LSL)/6*Std.dev
𝑝𝑟𝑜𝑐𝑒𝑠𝑠 𝑟𝑎𝑛𝑔𝑒
 Cpk : It is known as actual potential capability of a process. It is used widely for off
centre process. It considers process average and evaluates the process spread with
respect to where the process is actually located . The magnitude of Cpk relative to Cp
is a direct measurement of how off-centre the process is operating.
Cpk = min{USL-mean/3*std.dev, mean-LSL/3*std.dev}
Contd.
CASE STUDY:
MANUFACTURING OF PISTON RINGS :
The data given below is the example related to manufacturing of piston
rings for an automotive engine produced by Forging process. Twenty
five samples, each of size five have been taken and the inside diameter
is measured. The resulting data together with the sample means and
sample range values are given below in Table . This case has been taken
for checking the stability of process. For this purpose , Process
capability analysis is done with the help of control chart and process
capability indices.
Table: Data of Inside diameter of piston rings ( spec: 74.000 + 0.005)
CONTD.
Table: Data of Inside diameter of piston rings ( spec: 74.000+ 0.005)
Sample x1 x2 x3 x4 x5 Sample Range
Number Mean R
1 74.030 74.002 74.019 73.992 74.008 74.0102 0.038
2 73.995 73.992 74.001 74.011 74.004 74.0006 0.019
3 73.988 74.024 74.021 74.005 74.002 74.0080 0.036
4 74.002 73.996 73.993 74.015 74.009 74.0030 0.022
5 73.992 74.007 74.015 73.989 74.014 74.0034 0.026
6 74.009 73.994 73.997 73.985 73.993 73.9956 0.024
7 73.995 74.006 73.994 74.000 74.005 74.0000 0.012
8 73.985 74.003 73.993 74.015 73.988 73.9968 0.030
Control chart constants:
9 74.008 73.995 74.009 74.005 74.004 74.0042 0.014
10 73.998 74.000 73.990 74.007 73.995 73.9980 0.017 n d2 D3 D4 A2 Dk* D3*k D4*k A2*k
11 73.994 73.998 73.994 73.995 73.990 73.9942 0.008
12 74.004 74.000 74.007 74.000 73.996 74.0014 0.011 2 1.128 0 3.267 1.880 0.376 0.000 1.228 0.707
13 73.983 74.002 73.998 73.997 74.012 73.9984 0.029
14 74.006 73.967 73.994 74.000 73.984 73.9902 0.039 3 1.693 0 2.574 1.023 0.564 0.000 1.453 0.577
15 74.012 74.014 73.998 73.999 74.007 74.0060 0.016
4 2.059 0 2.282 0.729 0.686 0.000 1.566 0.500
16 74.000 73.984 74.005 73.998 73.996 73.9966 0.021
17 73.994 74.012 73.986 74.005 74.007 74.0008 0.026 5 2.326 0 2.115 0.557 0.775 0.000 1.640 0.432
18 74.006 74.010 74.018 74.003 74.000 74.0074 0.018
19 73.984 74.002 74.003 74.005 73.997 73.9982 0.021
6 2.534 0 2.004 0.483 0.845 0.000 1.693 0.408
20 74.000 74.010 74.013 74.020 74.003 74.0092 0.020 7 2.704 0.076 1.924 0.419 0.901 0.069 1.734 0.378
21 73.982 74.001 74.015 74.005 73.996 73.9998 0.033
22 74.004 73.999 73.990 74.006 74.009 74.0016 0.019 8 2.847 0.136 1.864 0.373 0.949 0.129 1.769 0.354
23 74.010 73.989 73.990 74.009 74.014 74.0024 0.025
24 74.015 74.008 73.993 74.000 74.010 74.0052 0.022
25 73.982 73.984 73.995 74.017 74.013 73.9982 0.035
Average 74.00118 0.0232
4
CASE ANALYSIS:
Usual Method of Control Charts and the Computation of Process Capability
Indices Control Limits for R-Chart are obtained as :
CL=𝑅 = 0.02324
UCL= D3 𝑅 = 0*0.02324 = 0
LCL = D4𝑅 = 2.115*0.02324 = 0.0492

Control limit for 𝑥 chart are obtained as follows :

CL= 𝑋 = 74.00118
UCL = 𝑋 + A2 𝑅 = 74.00118 + 0.577 * 0.02324 = 74.01549
LCL = 𝑋 - A2 𝑅 = 74.00118 – 0.577 * 0.02324 = 73.98777
By plotting the control limits, sample ranges and sample means, We get R- chart
and X bar chart as given below :
CONTD.

R-Chart X bar chart

CONTD.
Process capability indices calculation :
The manufacturing capability of a process can normally be evaluated in terms of process
capability indices and. The process capability indices obtained from the
σ = 𝑅 /d2 = 0.02324 / 2.326 = 0.0099
CP = USL – LSL/ 6σ = (73.95 – 74.05)/6*0.099 = 1.6681
Cpu = (USL - 𝑋 )/3σ = 74.00118 – 74.05 /3*0.099 = 1.6287
Cpl =( 𝑋 - LSL)/3 σ = 74.00118 – 73.95 /3*0.099 = 1.7075
CPK = min(Cpu,Cpl) = 1.62875
Conclusion:
From above analysis , It seems that process is stable i.e. process is in statistical control .All the
sample ranges and sample mean are within control limit . This Process is off-center ,because Cp
and Cpk values are not equal to each other.As Cpk value is greater than 1.33 , hence process is
capable. But not fulfilling the requirement of six sigma standard i.e. Cp value 2.
REFERENCES:
1. Maia T. Murlio, H. Elisa, Konrath C. Andrea,Alves C. Custodio. Application
of control charts for monitoring the machining process of the inside
diameter of a steel cylinder,International conference on industrial
engineering and operation management.Portrugal;2012.p ID 87.1-87.10 .
2. Valles Adan,Jaime Sanchez,N. Salvador,N. G. Berenice.Implementation of
Six Sigma in a Manufacturing Process: A case study,International Journal
of Industrial Engineering; 2009.p 171-181 .
3. Shah Samip, Shridhar Pandya, Gohli Dipti. Control chart: A statistical
process control tool in pharmacy;p 184-191 .
4. Kabir E. Md. , Boby I. Mahbubul S.M. , Lutfi Mustafa. Produvtivity
Imorovement by using Six Sigma, International Journal of Engineering
and technology; 2013. p 1056-1084 .