Aircraft Wing Damage

1. Six SigmaThe Continuous Improvement Culture Presentation ByThatavarti VenkataRadhaKrishnahttp://sa.linkedin.com/in/thatavartiradhakrishna

2. Aircraft Wing Damage

3. Baking

4. Saving How many of you run a project with an intention to save a Riyal for your organization ? How many of you wants to really save RIYAL for your organization

5. Problem How many of you are facing problems in your organization for the execution of various tasks? How many of you considered “Problem solving as an special project” at your organization?

6. My Problems Fiction between the business development and project management. Claims people runs a 30 days clearance cycle Saudi partner companies are really not able to add value Moving for one appointment to another, during the movement appointment 2 got cancelled – I came to know this info only after reaching the client place : Good part is client has communicated the cancellation on e-mail

7. Agenda • What is Six Sigma • History of Six Sigma • Six Sigma Methodology • Problem solving using DMAIC • Problem solving using DFSS • Sigma calculator

8. What is Six Sigma • Sigma is a Greek letter used to define the amount of variation in a process or procedure. Higher the sigma, lesser the variation. • Six Sigma is a rigorous and disciplined methodology that uses data and statistical analysis to measure and improve a company’s operational performance by identifying and eliminating defects in manufacturing and service-related processes. • Commonly defined as 3.4 defects per million opportunities.

9. History of Six Sigma • The roots of Six Sigma as a measurement standard can be traced back to Carl Frederick Gauss (1777-1855) who introduced the concept of the normal curve. • In 1920’s Walter Shewhart showed that three sigma from the mean is the point where a process requires correction . • Credit for coining the term "Six Sigma" goes to a Motorola engineer named Bill Smith. (Incidentally, "Six Sigma" is a federally registered trademark of Motorola). • GE implemented the Six sigma practices and pioneered in it.

10. Six Sigma Methodology There are two methodologies of problem solving • DMAIC - should be used when a product or process is in existence at your company but is not meeting customer specification or is not performing adequately. • DFSS – should be used when a product or process is not in existence at your company and one needs to be developed . • Tollgates are identified for each of these processes and tasks to be completed at each tollgate are listed.

11. Problem solving using DMAIC • DMAIC (Define , Measure, Analyze, Improve, Control) refers to a data-driven quality strategy for improving processes. The 5 process steps of the DMAIC process form tollgates where it needs to be checked that certain tasks are done. Define • the customer and their Critical to Quality (CTQ) issues • Voice of the customer (VOC) • Define project boundaries , start and stop of the project • Define process to be improved by mapping the process flow

12. Problem solving using DMAIC Measure - Develop a data collection plan for the process - Collect data from many sources to determine types of defects and metrics - Compare to customer survey results to determine the shortfall Analyze - Analyze the data collected and process map to determine root causes of defects and opportunities for improvement - Identify gaps between current performance and goal performance - Prioritize opportunities to improve - Identify sources of variation and Risk assessment.

13. Problem solving using DMAIC Improve • Create innovate solutions using technology and discipline • Develop and deploy implementation plan Control • Prevent reverting back to the "old way" • Require the development, documentation and implementation of an ongoing monitoring plan • Institutionalize the improvements through the modification of systems and structures (staffing, training, incentives)

14. Understanding DFSS DFSS - is the acronym for Design For Six Sigma • Unlike the DMAIC methodology, the phases or steps of DFSS are not universally recognized or defined -- almost every company or training organization will define DFSS differently • Used to design or re-design a product or service from the ground up • One popular Design for Six Sigma methodology is called DMADV ( Define, Measure, Analyze, Design, Verify) • Customer expectations and needs (CTQs) must be completely understood before a design can be completed and implemented

15. DMADV Define • Project goals and customer requirements (both internal and external) i.e.; SLA,the charter and the VOC Measure • Measure and determine the customer needs and specifications (CTQ) Analyze • Analyze the process options to meet the customer needs • Prepare the HLD and make a risk assessment

16. DMADV Design • Detailed designing of the process to meet the customer needs • Prepare a LLD to solve the problem • Prepare a pilot to test the design Verify • Verify the design performance and ability to meet the customer needs (pilot can be used for this)

17. Sigma Calculator Understanding the formula DPMO = (Total defects / Total opportunities) * 1000000 Process sigma = 0.8406 + SQRT(29.37-2.221*(ln(DPMO)))

18. Walk with knowledge you will never walk alone..