1. Chapter 5 Continuous Process Improvement
Create a system for constant and continuous improvement

2. Understand the Process: Variations are Major Enemies
Detecting mode (heavy dependence on inspection/testing/control): Fire fighting is not effective
Preventive mode (emphasis on “do it right the first time and all the time): Use FEEDBACK to take corrective actions so that the process can be continuously improved.

3. Process Model

4. Process Improvement Strategy: Finding Cost Effective Solution
Control existing process: i.e., statistical process control (SPC)
Optimize the process: i.e., design of experiment (DOE)
Change the system: hardware, software and brainware
New system: machine, human, materials, method

5. PDSA Cycle: Embedded in the Continuing System
Plan Do
Study
Act
Plan again …

6. Problem Solving: A Continuous Effort
Identify problems as an opportunity
Analyze the problem: to find root causes
Develop optimal and cost effective solutions
Implement changes: system wide
Study the results: worked or not? Need adjustment?
Standardize solution: Keep problems from reoccurring.

7. Six Sigma: Aim High Specification Limit Defective Rate +/- 3 sigma
0.27% (2700 ppm)
+/- 4 sigma
63 ppm
+/- 6 sigma
0.002 ppm (3.4 ppm if process is not centered)