Six Sigma Overview

Six Sigma is a disciplined process which, by using data, What is Six Sigma? Six Sigma is a disciplined process which, by using data, systematically reduces defects. The next several slides are a brief introduction to Six Sigma and to the video. Instructor Note: The following slides have been hidden to shorten the introduction Champion slides 12 to 16 BB slides 19 to 22 Process Overview slide 52 These slides may be used at the discretion of the instructor.

What is Six Sigma? Six Sigma is about stopping defects before they happen. Changes focus from fixing products to fixing processes so they make excellent products. Reduces defects most important to the customer

Success Tree of Six Sigma 6 s Continuous Improvement Success Sweet Fruit 5 s Wall, Improve Designs Bulk of Fruit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 s Wall, Improve Processes Low Hanging Fruit The 3.5/4 sigma wall is caused by lack of measurement systems, hypothesis testing, and DOE usage. The 5 sigma wall is a result of processes that were not designed from the start as 6 Sigma processes. (need DFSS – design for six sigma) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 s Wall, Beat Up Suppliers Ground Fruit

Methodology Overview

Six Sigma Phases D M A I C Phase I: Process Definition Phase II: Process Measurement A Phase III: Process Analysis I Phase IV: Process Improvement C Phase V: Process Control

Continuous Improvement The following visual illustrates how the system can work SUPPLIER CUSTOMER Process Step 1 Process step 2 Process step 3 RECORD DEFECTS RECORD DEFECTS RECORD DEFECTS RECORD DEFECTS RECORD DEFECTS DEFINE CONTINUOUS IMPROVEMENT MODEL TREND CHART PROCEDURE GOAL MEASURE TIME ANALYZE CONTROL Vital Few Identification ACTION PLAN IMPROVE ACTION NAME DATE

Six Sigma Breakthrough Steps Step 1 - Select Output Characteristic - Identify Process Input/Output Variables Step 2 - Define Performance Standards Step 3 - Validate Measurement System Step 4 - Establish Process Capability Step 5 - Define Performance Objectives Step 6 - Identify Variation Sources Step 7 - Screen Potential Causes Step 8 - Discover Variable Relationships Step 9 - Establish Operating Tolerances Step 10 - Validate Measurement System Step 11 - Determine Process Capability Step 12 - Implement Process Controls Define Measure Analyze Not firm break points between MAIC. Process sometimes loops. Second MSA refers to both vital Xs and if needed a finer measurement on Y. Note: At the end of this section there are slides that go through the 12 steps in more detail. Improve Control