2. Customer Expectations Standards Certifications Inspections Packaging Others

3. Standards Identify applicable product standards Identify applicable test standards Understand and implement

4. Certifications Quality Management System (ISO 9001:2008) Environmental Management System (ISO 14001:2004) OHSAS 18001:2000 CE Mark

5. Inspections Second party inspection Third party inspection Self inspection

6. Packaging Proper packaging material Export worthy packaging Usage of symbols Counter presence Packaging cost

7. Others Cleanliness Finish Compliance Timiliness Variation

8. Methods Benchmarking Reliability Studies FMEA QFD Six Sigma

10. What is Six Sigma? 1. Philosophy: We should work smarter, not harder. 2. Business strategy: We gain a competitive edges in Quality, Cost, Customer Satisfaction. 3. Statistical measurement: We measure defect rates in all processes through an expanding statistical concept.

11. What is Six Sigma? Sigma is a statistical measure of variation from the average For a manufacturing process, the sigma value is a metric that indicate how well that process is performing. The value of 1 sigma is one standard deviation from the mean.

12. Six Sigma Approach Combines some of the best technique of the past with recent breakthroughs in management thinking and plain old common sense. The term ‘Six Sigma’ is a reference to a particular goal of reducing defects to near zero.

13. Benefits: The goal of Six Sigma is to increase profits by eliminating variability, defects and waste that undermine customer loyalty.

14. Goals of Six Sigma To achieve Zero Defect (3.4 PPM) in all outputs of the company through: a) Measurement of defects in six sigma scale b) Process re-design to improve capability c) Involvement of all Employees

15. Six Sigma Belts: Black Belt: Someone who either coaches or actually leads a Six Sigma team. Master Black Belt: A person who coaches a large number of Six Sigma teams. Green Belt: Employees who have received basic Six Sigma training.

16. Calculating Sigma Step 1: Calculating Defects per Unit (DPU) DPU = Total number of defects Total number of units

17. Calculating Sigma Step 2: Calculating Defects Per Million Opportunities for error (DPMO) DPMO = DPU X 1,000,000 No. of opp. for error

18. Calculating Sigma Step 3: Correlate the DPMO to the chart showing correlation between “defects per million opportunities” and sigma levels.

19. Sigma and it’s DPMO Sigma (σ) valueDefects per million opportunities (+/-) 2308, 537.0 (+/-) 366, 810.0 (+/-) 3.522, 750.0 (+/-) 46, 210.0 (+/-) 4.51,350.0 (+/-) 5233.0 (+/-) 5.532.0 (+/-) 63.4 SIGMA CONVERSION CHART

20. Tolerance UCL USL LCL LSL X +3σ+6σ-3σ-6σ

21. Case Example STEPACTIONEQUATIONCALCUL. 1.How many units were put through the Process? --1283 2.How many came out error free? --1138 3.Compute the yield of the process. step 2/ step 10.8870 4.Compute the defect rate.1 – step 30.113 5.Compute the number of potential things that could create a defect. N number of CTQs (Critical To Quality parameters) 24

22. Case Example STEPACTIONEQUATIONCALCUL. 6.Calculate the defect rate per CTQ characteristics Step 4/ step 50.0047 7.Compute the defects per million opportunities Step 6 X 1,00,000 4709 8.Convert the DPMO into sigma value using the sigma conversion chart --4.1 sigma 9.Draw conclusionsSlightly above average performance

23. Six Sigma Tools: There are two six sigma methodologies: DMAIC (define, measure, analyze, improve, control) DMADV (define, measure, analyze, design, verify)

24. Six Sigma Tools: For existing processes DDefine MMeasure AAnalyze IImprove CControl

25. Six Sigma Tools: For new processes DDefine MMeasure AAnalyze DDesign VVerify

26. The Journey Six Sigma aims at continual improvement through the journey starting from the existing sigma level, gradually moving towards six sigma level and beyond.