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Six Sigma

Six Sigma. TOTAL QUALITY MANAGEMENT. 6 s. What is ‘Six Sigma’?. Six Sigma is a quality measure & improvement program developed by Motorola. It is used to reduce product defects, improve quality and increase profitability. What Does Sigma Mean?.

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Six Sigma

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  1. Six Sigma TOTAL QUALITY MANAGEMENT 6 s

  2. What is ‘Six Sigma’? • Six Sigma is a quality measure & improvement program developed by Motorola. • It is used to reduce product defects, improve quality and increase profitability.

  3. What Does Sigma Mean? • Sigma is a Greek letter sand is used in statistics to denote variation, or ‘standard deviation’. • To control a process to the point of six sigma means to control defects to 3.4 per million items.

  4. The Use Of Six Sigma • By identifying factors which are critical to quality, we can: • Reduce process variation; • Improve capabilities; • Increase stability; • Work towards ZERO DEFECTS.

  5. Zero Defects • If we can measure how many defects we have in any given process, then we can systematically work towards eliminating them and get as close as possible to zero defects.

  6. Key Elements of Quality 1. The Customer. 2. The Process. 3. The Employee.

  7. 1. The Customer • Defines quality; • Expects performance, reliability, competitive price, on time delivery, service, correct transaction processes, etc. • Being good is not enough – customers need to be delighted!

  8. 2. The Process • There is a need for us to look at our business from the customer’s perspective. • That is, to look at our processes from the outside in.

  9. 3. The Employee • Lets put it simply: PEOPLE CREATE RESULTS!

  10. The DMAIC Model • At the heart of Six Sigma is a systematic method for analyzing & improving business process, called DMAIC. • The DMAIC model includes five phases.

  11. Five DMAIC Phases • Define opportunities; • Measure performance; • Analyse opportunity; • Improve performance; • Control performance.

  12. DMAIC Phases - Define • Measure performance • Various tools can be used once we have a measurement plan. • Benchmarking, S.P.C., calculation of process sigma, R & R studies, etc.

  13. DMAIC Phases - Measure • Define opportunities • This is the step we take to find exactly what the requirement, measure, or concern is. • Without defining, we cannot perform the other elements!

  14. DMAIC Phases - Analyse • Analyse • Once we have measured data we can analyse it using cause & effect analysis; financial assessment, value added analysis etc.

  15. DMAIC Phases - Improve • Improve • Having analysed our data we can take steps to improve the process using Design of Experiments, F.M.E.A., Poka-Yoke, etc.

  16. DMAIC Phases - Control • Control • Once we have made process improvements we need to control the process using Kaizan, Control charts, 5c etc.

  17. The DMAIC Process - Example • Lets look at an example: • A company is having parts failing inspection after machining. • Lets see how the DMAIC process could be used…

  18. The DMAIC Process – Example: Define • Define: • Inspection are rejecting high number of parts after final machining.

  19. The DMAIC Process – Example: Measure • Measure: • Yield obtained; • Number of defects in total measured so that standard deviation can be defined.

  20. The DMAIC Process – Example: Analyse • Analyse: • Operators; • Material; • Identified variables that could impact production; • Different experiments conducted; • Range of acceptable levels determined.

  21. The DMAIC Process – Example: Improve • Improve: • Operating instructions changed; • Production levels bought into line with capacity; • Final production yield increased!

  22. The DMAIC Process – Example: Control • Control: • Control charts introduced for each machine; • Corrective Action Plan provided for defects.

  23. Six Sigma • So as can be seen from the example, the DMAIC process was applied. • Remember that there may not be a ‘quick fix’ and that resources need to be applied to a problem.

  24. Six Sigma Belts • Experts at Six Sigma disciplines are often referred to as ‘Master Black Belts’. • These experts often train others in the disciplines, being ‘Black Belts’ and ‘Green Belts’.

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