six sigma training - in a nut shell -1
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SIX SIGMA IN A NUT SHELL
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What is Six-Sigma?
- Traditional Six Sigma focuses on reducing
variation and increasing process capability
in order to reduce defects.
- A process that reaches the six sigma level
will have less than 3.4 defects for every
million parts produced.
SIXSIGM
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Six Sigma Objectives- Center the process to match the target- Reduce the variation in the process to the point
that 6 standard deviation of your process are in
between the upper and lower specification limits.
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Lean is a simple strategy that focused on
elimination of waste, variation and work
imbalance.
Each step must create value for the Customer!
EVERY quality problem that has ever occurred is
caused by a process that
has shifted too far from target
or has too much variation.
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Lean Looks at Value!
VALUE ADDING ACTIVITY
Changes the information or Product
Done right the first time
Customer is willing to pay for it
(Customer cares)
Process / Operation that takes
time, resources or space, but do
not add value to the product or
services
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NON-VALUE ADDING ACTIVITY
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Traditional Six Sigma focuses on;
- Quality
- Capability
Lean is focusing on;
- Capacity / Efficiency- Lead Time / Cycle Time
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SIXSIGM
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TYPICAL SIX SIGMA TOOLS
Capability Studies
Gage Repeatability and
Reproducibility Studies
Statistical Process Control
Pareto Analysis
Histograms
Design of Experiments
C&E matrix
Control Plans
Statistical Tolerance Analysis
Hypothesis Testing
TYPICAL LEAN TOOLS
Pull System
Kanban
Error Proofing (Poka Yoke)
Value Stream Mapping
Takt Time Analysis
Quick Changeover (SMED)
One Piece Flow
Standard Operations
Spaghetti Diagrams
Rolled Throughput Yield
Value-Added Analysis
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Six Sigma has evolved from a collection of toolsto become a methodology for improvement.
The methodology is made up of 5 phases;
DefineMeasure
Analyze
Improve
Control
A scientific and data-driven approach to find
the optimal solution to a business problem.
SIXSIGM
AKNOWLEDGE
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oLean Six Sigma is a methodical and scientific
continuous improvement and business
optimization strategy.
oIt is a combination of two main concepts;
1. Lean
2. Six-Sigma
oLean Six Sigma gives business the benefits that
eventually lead to increased profitability and
cash flow.
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AKNOWLEDGE
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In the context of ISO TS16949:2009,
Lean is about making a process EFFICIENT
(Simple) and
Six-Sigma is making it EFFECTIVE (Less Defect)
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Six Sigma can be understood/perceived at three levels:
1.Metric:
3.4 Defects Per Million Opportunities. DPMO allows you to take
complexity of product/process into account. Also we want to be
Six Sigma at Critical Control Point (CCP) and not the whole
unit/characteristics.
When your process Sigma Level:
1. 6.0 sigma = 3.4 DPMO
2. 5.0 sigma = 230 DPMO3. 4.0 sigma = 6210 DPMO
4. 3.8 sigma = 10700 DPMO
5. 3.0 sigma = 66800 DPMO
6. 2.0 sigma = 308000 DPMO
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2. Methodology:
Structured problem solving roadmap and tools.
CONTROL
IMPROVE
ANALYZE
MEASURE
DEFINE
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SIXSIGM
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Define CCP
Measure CCP
Analyze
Cp & Cpk
Improvement
Reconfirm
Part
Accuracy
& Cp Cpk
Run DOE Control
If Cp > 1.33 and Cpk >1.00
If Cp < 1.33 and Cpk 90% and
Cp > 1.33 and Cpk >1.00
If Accuracy < 90% and
Cp < 1.33 and Cpk
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3. Philosophy:
Reduce variation in your business and take customer-focused,data driven decisions.
Two measures are commonly used to assess the capability of a
process:
1) Process Capability Ratio,
Cp = Upr Spec Lwr Spec
6-SigmaThis ratio will show us the process variation and this ratio must
greater or equal to 1.33
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Process Capability Index,
Cpk = Minimum of X Lwr Spec , Upper Spec - X
3-Sigma 3-Sigma
This Index will showwhere the process mean is located relative
to the specifications.
This index must greater or equal to 1.00
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1. Training
Training Module Participant Man-Hrs
1) Improvement Methodology Line Function 3-hrs
2) SPC
QC Inspector &
Line Function
3-hrs
3) 6-Sigma Awareness Training 3-hrs
4) Measurement Technique 2-hrs
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2) D- Define
i. To define CCP based on historical problem & discussion with customer.ii. To consider the Fitting, Form & Function and consider historical feedback.
Example
Part Name: C/Mbr Frt Floor Frt Lower Assy LH
Part Number: PW 839007X1
Legend
CCP
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3) M- Measurei. To measure 30 pcs for each part based on CCP & conducted by QC Inspector.
ii. Before taking any measurement, it is essential to conduct Gage Reproducibility
and Reliability (Gage R&R) Study to quantify variation due to measurement
process, including the gage and those using the gage.
Why ?
Total process variability = f (Measurements , Machines, People, Material, Methods,Environment)
Identify if measurement variation is a significant problem so action can be taken.
SIXSIGM
AKNOWLEDGE
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How to do the Gage R&R Study?
Use Variable Gauge Short Form StudyWorksheet
Use one gage, five randomly picked parts
and two operators. Number the parts 1 to 5
Have the operators measure each part
independently and record results on the
worksheet.
Calculate the measurement range for each
part. Range = highest measured reading
lowest measured reading.
Calculate the average range for the
measurement system:Rm = sum of range values
number of range values
Calculate combined Repeatability &
Re-producability (R&R) variation :
R&R = Rm X 4.33
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Calculate percentage of R&R over the equipment tolerance range
% of tolerance Range = R&R
Tolerance Range
Industry Standard for Acceptance of Gage % R&R
Under 10% error the measurement
system is acceptable
10% to 30% error May be acceptablebased on importance of application, cost
of gage, cost of repairs , etc.
Over 30% error measurement system
needs improvement. Make every effort
to identify the problems and have themcorrected.
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Take data on the CCP n, sample size = 30 pcs.
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4) A- Analysesi. To analyze Cp & Cpk for each CCP by using Excel software.
ii. Target Cp > 1.33 Cpk > 1.00 (Subject to respective customers expectation)
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5) I- Improve
i. To improve Assembly Finish Good (FGA) & Loose (Stamping) Finish Good (FGL) bythe support from Jig Maintenance & Dies Maintenance.
ii. Identify the cause of parts instability & make an improvement
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6) C- Controli. To control the improvement activity done by 6- Sigma team by using:
a. SPC
b. Direct Measurement
c. Periodical Inspection
a. SPC
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b. Direct Measurement
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c. Periodical Inspection Quality Check Sheet
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STANDARD FLOW
CONCEPT
HOLDING STOCKS
FOR IHS, IHA AND
FGA
REQUIRED
SPACE
PALLETS MOVEMENT
MORE PEOPLE
LEAN FLOW
CONCEPT
NO HOLDING STOCKS
FOR IHS AND IHA
REDUCED HOLDINGSTOCKS FOR FGA
REQUIRED
LESS SPACE
LESS PALLETLESS MOVEMENT
LESSER PEOPLE
STAMPING
IHS (IN HOUSE
STAMPING) STOCKS
ASSEMBLY
IHA (IN HOUSE
ASSEMBLY) STOCKS
ASSEMBLYFGA STOCKS
DELIVERY
STAMPING
IHS
ASSEMBLY
IHA
ASSEMBLY
FGA STOCKS
DELIVERY
Example of Lean Flows
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3 Option of Lean Six-Sigma
1. One Piece Flow Forward
2. One Piece Flow Backward
3. Outsourcing
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One Piece Flow Forward Bringing IHA process to
the MODULAR line
Small Sub Assy
Delivery to Logistic
IHA storage
Module Line
Small Sub Assy Delivery to LogisticModule Line
ILLUSTRATION 1
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One Piece Flow Backward Bringing IHA
process to Stamping line and converting it intoIHS or FGA parts
Delivery to logisticSmall Stamping Small Sub Assy
Small Sub Assy Delivery to LogisticIHS storageSmall Stamping
ILLUSTRATION 2
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OUTSOURCING Getting our supplier to do
process for us
ILLUSTRATION 3
Small Sub Assy Delivery to LogisticIHS storage Module LineIHA storage
Sub to ContractorModule Line Delivery to Logistic
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Reduce Production Lead time
Reduce WIP Inventory and Raw
materials
Reduce Finished Good Inventory
Reduce unnecessary overtime
Reduce manpower
Increase productivity (pieces/labor
hour)
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6.1 Defect ReductionReduction of defect at all levels (at customers & in-house)
6.2 Production/ Quality Improvement
Prevent defect by reducing variation in 4M.a. Man- Now the shop floor leader understands on the methodology
of 6-Sigma & able to prevent defect from recurring.
b. Machine (Dies & jigs)- Maintained the dies & jigs before defect
occurs & reducing down time for repairing activity.
c. Material (Parts & Component)- Maintained/ increased the
accuracy of parts & component after improvement activity
d. Method- Systematic ways of improving the parts accuracy based on
DMAIC.
e. Measurement- Now the QC Inspector & line function are able toperform the correct way of taking data thus ensuring high reliability
& accuracy.
SIXSIGM
AKNOWLEDGE
C S F
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