management consulting and iso consulting services - green dot sigma and various levels of sigma...
TRANSCRIPT
FICCI CE
FICCI CE
FICCI CE
Accuracy & Precision - The twin objectives of world class
manufacturing.
FICCI CE
Accuracy & precision can be best explained by using the analogy of a rifle firing at a target.
Accuracy & precision
FICCI CE
Accuracy and precision
With the center of the target taken to be the true value of the characteristic being measured and by the rifle shots representing the measured values, there are four combinations of accuracy and precision as depicted in the following slides.
FICCI CE
Inaccurate and imprecise
FICCI CE
Accurate and imprecise
FICCI CE
Precise but inaccurate
FICCI CE
Accurate and precise
FICCI CE
Objectives of world class manufacturing
The objective of world class manufacturing a is to continuously achieve higher levels of accuracy & precision in the manufacturing processes.
FICCI CE
Sigma in statistical terms
Standard deviation is also referred to as the Greek letter sigma in quality management literature. Consequently process variation can be described by how many sigmas ( i.e how many multiples of standard deviation or SD ) fit within the specification limits.The higher this number, the better is the quality and vice versa.
Sigma is a statistical measure of the quality consistency for a particular process / product.
FICCI CE
Sigma process
From a sigma process we come to know that at what distance, in terms of the standard deviation, the specification limits are placed from the target value.
FICCI CE
Move beyond 3 sigma
Until a few years back all statistical process controls were designed on the basis of 3 sigma limits. It is only in the recent years that this concept has been challenged and the organizations have started looking for quality levels beyond 3 Sigma.
FICCI CE
3 Sigma process
LSL USLMean=8SD = 2
- 3 SD + 3 SD
2 3 4 5 6 7 8 9 1210 16151413111
Note : LSL is Lower specification limit and USL is Upper specification limit.
FICCI CE
4 Sigma process
2 3 4 5 6 7 8 9 1210 16151413111
LSL USLMean=8SD = 1.33
- 4 SD + 4 SD
FICCI CE
2 3 4 5 6 7 8 9 1210 16151413111
LSL USLMean=8
SD = 1.07
- 5 SD + 5 SD
5 Sigma process
FICCI CE
LSL USLMean=8SD = 1
- 6 SD + 6 SD
2 3 4 5 6 7 8 9 1210 16151413111
6 Sigma process
FICCI CE
Precision
Lesser the standard deviation of the process, more precise or consistent is the process
FICCI CE
3 Sigma Vs 6 Sigma
The goal of Six Sigma program is to reduce the variation in every process to such an extent that the spread of 12 sigmas i.e. 6 Sigmas on either side of the mean fits within the process specifications. The figure on next slide shows what this looks like.
FICCI CE
2 3 4 5 6 7 8 9 1210 16151413111
LSL USL
6 Sigma curve
3 Sigma curve
3 Sigma Vs 6 Sigma
In a 3 sigma process the values are widely spread along the center line, showing the higher variation of the process. Whereas in a 6 Sigma
process, the values are closer to the center line showing less variation in the process.
FICCI CE
3 Sigma Vs 6 Sigma
The comparison on the previous slide also shows a process in which the process spread of Six Sigmas (ie. 3 Sigmas on either side just fits within the specifications). In this case one must be extremely careful to ensure that the process average never slips off the target, otherwise the curve will shift and non-conforming items will increase. With Six Sigma requirement the process mean can shift by as much as 1.5 sigma before the likelihood of non-conforming items is increased. Even if the process mean does shift off center by as much as 1.5 sigma, only 3.4 non-conforming items per million parts should result.
FICCI CE
Amount of process shift allowed
2 3 4 5 6 7 8 9 1210 16151413111
LSL USL
SD = 1
1.5 SD 1.5 SD
FICCI CE
Sigma levels and defect rate
Quality level % Quality Defective PPM*
3 Sigma 99.73 66807
4 Sigma 99.9937 6210
5 Sigma 99.999943 233
6 Sigma 99.9999998 3.4
*Parts Per Million
FICCI CE
Sigma levels & Cost of quality
Sigma Defect rate(PPM) Cost of quality Competitive level
3.4 <10%
233 10-15%
6210 15-20%
66807 20-30%
308537 30-40%
6,90000 >40%
World Class
Industry Average
NonCompetitive
6
5
4
3
2
1
FICCI CE