1. Dr.RAMESH LAKHE,SQMS,NAGPUR( Iss/Rev.:01/00 Dt.28.07.16)
S I X S I G M A
A n A w a r e n e s s
P r o g r a m m e
Dr.RAMESH LAKHE,SQMS,NAGPUR( Iss/Rev.:01/00 Dt )

2. Learning Objectives
At the end of the training and certification process, the Six Sigma Green Belt’s will be able to:
Identify, lead breakthrough projects and achieve significant results which impact the bottom-line.
Implement the Six Sigma methodologies.
Use basic statistical tools.
Facilitate the Teams.
Support BB in Six Sigma deployment.

3. Six Sigma: An Awareness
A w a r e n e s s T o u r
Six Sigma : Introduction
Six Sigma: The History
Six Sigma: The Philosophy
Six Sigma: The Statistical Representation
Six Sigma: The Deployment & Benefits

4. Six Sigma: The Introduction

6. Cost of Poor Quality Organisation Ocean Prevention Cost Appraisal Cost
Lost Management Cost
Organisation Ocean
Maintenance Cost
Lost Business, Goodwill cost
Rerun Cost
Project Rework Cost
Lost Opportunity, Lost Assets Cost
Lost Credibility Cost

7. Six Sigma
A Management driven, scientific methodology for product and process improvement which Reduces Cost of Poor Quality, Process Variation & Defect Rates and creates breakthroughs in Quality, Cost performance and Customer satisfaction
Customer Satisfaction + Efficient Systems = Improved Profitability

8. What is Good Quality ?…… 99% ??
99% Quality means………
5000 incorrect surgical operations per week !
200,000 wrong drg prescriptions each year !
2 Short or Long landings at Airport each day !
Unsafe Drinking Water for 15 min/day !
20,000 lost artcles of mail per hour !
No electricity for 7 hrs per month !

9. WHAT IS SIX SIGMA Classical view on Quality
99% Good (3.8 Sigma)
The Six Sigma view of Quality
% Good (6 Sigma)
20,000 lost articles of mail per hour
Seven articles lost per hour
Unsafe drinking water for almost 15 minutes each day
One unsafe minute every seven months
5,000 incorrect surgical operations per week
1.7 incorrect operation per week
Two short or long landings at most major airports each day
One short or long landing every five years
600 new policies / month delivered with errors
1 new policy delivered with errors every 5 months
180,000 lost calls each year
61 lost calls each years
No electricity for almost seven hours each month
One hours without electricity every 34Years

10. Six Sigma: The History

11. Six Sigma: History ????!!! Motorola 1/20 th of Defects !!
Motorola’s Quassar TV set plant in US sold to Japanese for the reasons of poor Productivity & Yield started doing extremely well under Japanese management !!! TV sets were produced with 1/20th the no. of defects that were produced by Motorola !
They did this using the same workforce, technology & design… making it clear that the problem was Motorola’s management !
Quassar TV Plant

12. full scale on Six Sigma…!!
Six Sigma: History
A Paper by Bill Smith….
If a product was found defective & corrected during the production process, other defects were bound to be missed and found later by the customer during early use of the product….
However, when the product was manufactured error free, it rarely failed during early use by the consumer…....
In 1985, Bill Smith,
an engineer at
Motorola
presented a paper
which concluded
that….
In 1986, Motorola went
full scale on Six Sigma…!!

13. BENEFITS AT GENERAL ELECTRIC
Ten-fold increase in the life of CT scanner X-ray tubes in their medical devices section
Improved yield resulting in increased capacity without additional investments at Superabrasives their industrial diamond business

14. Sixty-two percent reduction in turnaround time at the repair shops of their railcar leasing business
Addition of 300 million pounds worth of new capacity. This was equivalent to adding a new plant.
Linked bonuses to six sigma introduction

15. The Development of Six Sigma
Jack Welch launched Six Sigma at GE in Jan,1996
1998/99 - Green Belt exam certification became the criteria for management promotions
2002/03 - Green Belt certification became the criteria for promotion to management roles GE
the company that perfected Six Sigma

16. Companies Adopting six sigma
Du Pont, Ford,Hero Motors, HDFC, Infosys,Wall Street,Cummins
Mumbai Dubbawalla---better than 6 sigma---2,00,000 tiffin boxes per day by 5000 dabbawalls to different parts of mumbai
Picki up-bus-local-bus-destination—change of hands
Errors reported 1 in 60,00,000 deliveries
6.6 sigma level
Coding system
Prince Charles---invited for marriage in 2005

17. Six Sigma: The Philosophy

18. Philosophy: make fewer mistakes in all that we do
Is about the abatement of risk in everything a business does or delivers.
All defects or errors represent risk but not all forms of risk can be characterized in terms of defects.
Is a new science of doing business based on data driven factual approach
Uses methodology
Six Sigma Problem Solving (DMAIC)
Design for Six Sigma (DFSS: Design For Six Sigma)/(DMADV:De)
Is management based on PDCA principle

19. Statistical Representation
Six Sigma:
Statistical Representation

20. Std. Devn. Variation = (Xi-Xbar) Deviation  Sigma () n-1 Variance
What is Sigma ( ) ?
A Greek symbol for measuring performance variation
Eg.
Xi = 10, 12, (Mean)Xbar = 12
n: No. of Readings Here: 3
Std. Devn. 2
Variation =
(Xi-Xbar)
Deviation 
Sigma ()
n-1
Variance

21. LSL: Lower Specification Limit, USL: Upper Specification Limit
What is 6 Sigma ?
A < 3  Situation
Cp<1
Parts
out of
Specs
LSL
Target (Process Mean)
USL
LSL: Lower Specification Limit, USL: Upper Specification Limit

22. What is 6 Sigma ?
A 3  Situation
Cp=1
All in
Specs
LSL
Target
USL

23. What is 6 Sigma ? A 6  Situation Cp=2 Only 50% of tol. used LSL
Target
USL

24. What is 6 Sigma ? Process Shift Without LSL USL
-6
-2
-1
+1
+2
+3
+4
+5
+6
-5
-4
-3
Xbar
Spec Limit Percent Defective ppm
± 1 ,17,300
± 2 ,500
± 3 ,700
± 4
± 5
± 6

25. 1.5 Shift: Rational
As the process is not perfect, there is consideration of 1.5shift.
Now in most cases, the process mean doesn’t stay exactly in the centre of the specification limit. The actual location of the mean is closer to one side than the other. This is called the Shift of the Mean

26. What is 6 Sigma ? With ± 1.5 Shift LSL USL
-1.5
+1.5
LSL
USL
-6
-2
-1
+1
+2
+3
+4
+5
+6
-5
-4
-3
Xbar
Spec Limit Percent Defective ppm
± 1 ,97,700
± 2 ,08,700
± 3 ,810
± 4 ,210
± 5
± 6

27. Process Performance Levels
CAPABILITY
REJECTIONS
NO SHIFT
WITH SHIFT
OF 1.5 SIGMA
SIGMA QAULITY
LEVEL
Cp = 2.00
0.002 PPM
3.4 PPM 6
12 
Cp = 1.66
0.57 PPM 5
233 PPM
10  4
63 PPM
6,210 PPM
Cp = 1.33
8 
Cp = 1.00
2700 PPM 3
66,807 PPM
6 
LSL
USL
NOTE :  

28. Sigma Level: Tabular Representation
DEFECT RATE
(PPM)
COST OF POOR QUALITY(% OF SALES)
COMPETITIVE LEVEL 6σ
3.4
< 10%
WORLD CLASS 5σ
233
10%- 15% 4σ
6210
15%- 2%
INDUSTRY AVERAGE 3σ
66807
20%-30% 2σ
308537
30%-40%
NON-COMPETITIVE 1σ
690000
> 40%

29. SIX SIGMA IMPLEMENTATION HELP
TO REDUCE VARIATION
TO REDUCE DEFECTS/DEVIATIONS
TO IMPROVE YIELD/PRODUCTIVITY
TO ENHANCE CUSTOMER SATISFACTION
TO IMPROVE THE BOTTOMLINE

30. This is What , is 6 Sigma ?
If the Pilot can always land the Aircraft within 50% of Runway area…… He is of Six Sigma Quality !
50% of Tol Band
Target
LSL
USL

31. Organization & Benefits
Six Sigma:
Organization & Benefits

32. Six Sigma: Organization
Champion
Master
Black Belt
Black Belts
Green Belts

33. Six Sigma: Roles & Responsibility
 Champions
Senior management
Promotion and integration of Six Sigma implementation across the organisation.
Master Black Belts (Normally Executed/leaded 10+ Projects )
assist champions and mentor Black Belts and Green Belts.
May be external or Internal consultants
ensuring that Six Sigma techniques are applied consistently and correctly.

34. Black Belts (Normally Executed/Leaded 5+ Projects)
operate under the guidance of a Master Black Belt, delivering the Six Sigma projects.
train and mentor the green belts
 Green Belts (Normally Fresher/1-2 Projects)
employees who take up Six Sigma implementation along with their other job responsibilities,
under the guidance of Black Belts as part of the Six Sigma project.
are trained in most of the tools outside of advanced statistical techniques.
 Yellow Belts
Not always designated, but if so, these are employees within the target areas used to implement, monitor and control the improved processes.
Training in basic Six Sigma awareness

35. APPLICATION BENEFITS OF SIX SIGMA
Six sigma can be applied to various sectors like Manufacturing and Service with various specializations like Mechanical, Chemical, Electrical, Engineering Design, Computer Science, IT etc.
Benefits-
Generates sustained success
Sets a performance goal for everyone
Maximize Product/Service Quality. (Develop Close to Zero Defect Products/Services)
Increase Sales
Increase overall Organizational Productivity
Reduce Waste
Save Costs
Make the Organization a Data-driven organization
Faster Cycle Time
Empower Employees
Enhances value to customers
Accelerates the rate of improvement
Promotes learning and cross-pollination
Executes strategic change etc.

36. Thank You