UNIT 5

Six Sigma Concepts Six Sigma Six Sigma concepts are introduced by Bob Galvin, Chief executive officer, Motorola corporation to enhance the quality and reliability of their products Sigma (σ) designates the distribution of the mean of any process

Six Sigma Concepts Six Sigma Six Sigma is an approach for improving performance for producing better products or services with best quality. It is a methodology for disciplined quality improvement i.e., the focus is on improving the capability of the process thro’ data collection, analysis and action for enhancing the product value for the customer.

Six Sigma Concepts Six Sigma is a business management strategy It seeks to identify and remove the causes of defects and errors in manufacturing and business processes. It uses a set of quality management methods, including statistical methods, and creates a special infrastructure of people within the organization ("Black Belts" etc.) who are experts in these methods

Six Sigma Concepts Sigma is the Greek letter representing the standard deviation of a population of data. Sigma is a measure of variation (the data spread) σ μ

Six Sigma Concepts Variation means that a process does not produce the same result (the “Y”) every time. Some variation will exist in all processes. Variation directly affects customer experiences.

Six Sigma Concepts Sigma Level: A value from 1sigma to 6 sigma signifies the maximum number of defects per million A process that can achieve “±6 σ” capability can be expected to have a defect rate 3.4 parts per million (ppm). With the inclusion of Six Sigma into a sound business system, the major ingredients of a Total Quality Management System are usually in place Six Sigma’s goal is the near elimination of defects from any process, product, or service.

DPMO – Defects per million opportunities Six Sigma Concepts Sigma % Good % Bad DPMO 1 30.9% 69.1% 691,462 2 308,538 3 93.3% 6.7% 66,807 4 99.38% 0.62% 6,210 5 99.977% 0.023% 233 6 99.9997% 0.00034% 3.4 DPMO – Defects per million opportunities

Six Sigma Step 1: Identify the product you create or the service you provide. In other words ... WHAT DO YOU DO? Step 2: Identify the Customer(s) for your product or service, and determine what they consider important i.e. Customer Requirements In other words ... WHO USES YOUR PRODUCT AND SERVICES? Step 3: Identify your needs (to provide product/service so that it satisfies the Customer) In other words ... WHAT DO YOU NEED TO DO YOUR WORK?

Six Sigma Step 4: Define the process for doing your work In other words ... HOW DO YOU DO YOUR WORK? Step 5: Mistake-proof the process and eliminate wasted efforts using... In other words ... HOW CAN YOU DO YOUR WORK BETTER? Step 6: Ensure continuous improvement by measuring, analyzing and controlling the improved process using DMAIC - (Define, Measure, Analyze, Improve, Control) In other words ... HOW PERFECTLY ARE YOU DOING YOUR CUSTOMER-FOCUSED WORK?

Six Sigma Methodologies 2 key methodologies – DMAIC & DMADV Define Measure Analyze Improve Control Define Measure Analyze Design Verify

Six Sigma Methodologies Both have 5 fundamental stages – for the improvement in process performance; these stages are based on Deming’s improvement PDSA cycle 5 stages of DMAIC Define Measure Analyze Improve Control

SSM:DMAIC Define high-level project goals and the current process. Measure key aspects of the current process and collect relevant data. Analyze the data to verify cause-and-effect relationships. Determine what the relationships are, and attempt to ensure that all factors have been considered. Improve or optimize the process based upon data analysis using techniques like Design of experiments. Control to ensure that any deviations from target are corrected before they result in defects. set up control mechanisms and continuously monitor the process.

SSM: DMADV or DFSS Define design goals that are consistent with customer demands and the enterprise strategy. Measure and identify CTQs (characteristics that are Critical To Quality), product capabilities, production process capability, and risks. Analyze to develop and design alternatives, create a high-level design and evaluate design capability to select the best design. Design details, optimize the design, and plan for design verification. This phase may require simulations. Verify the design & implement the production process and hand it over to the process owners.

Quality Management Tools used in 6-Sigma FMEA Histogram Axiomatic Design Control Chart Cost-benefit analysis CTQ Tree Pareto Chart & Run Chart Regression & Root Cause Analysis TRIZ SIPOC (Suppliers, Inputs, Process, Ouputs, Customers) Analysis Etc……..

Six Sigma Companies

CMMI – Capability Maturity Model Integration CMMI defines a measure of the effectiveness of software global practices CMMI is a model that consists of best practices for system and software development and maintenance. It was developed by the Software Engineering Institute (SEI) at Carnegie-Mellon University The model may also be used as a framework for appraising the process maturity of the organization

CMMI – Capability Maturity Model Integration CMM establishes 6 process maturity levels where in each level, CMM defines key activities required Level 0: Incomplete Level 1: Initial Level 2: Repeatable Level 3: Defined Level 4: Managed Level 5: Optimizing

CMMI – Capability Maturity Model Integration Level 0: Incomplete – Process area may have not been performed or does not achieve all goals defined by CMM Level 1: Initial In this initial level, only few process may be defined & success is depends upon individual effort

CMMI – Capability Maturity Model Integration Level 2: Repeatable This level used to keep track schedule, cost, & functionality. Some process may require to utilize earlier success on project (project management, process discipline) the process is used repeatedly

CMMI – Capability Maturity Model Integration Level 3: Defined – In this level, all software process are standardized, documented & integrated. This level includes all the characteristics of Level 2 Level 4: Managed – Both software process & products are understood with detailed measure. This level includes all characteristics of Level 3.

CMMI – Capability Maturity Model Integration Level 5: Optimizing In this level, continuous process improvement is enabled by feedback from the process & from testing ideas.

CMMI – Capability Maturity Model Integration Note: Within each of these maturity levels are Key Process Areas (KPAs) which characterize that level, and for each KPA there are five definitions identified: Goals Commitment Ability Measurement Verification