A short introduction

Hans van VeenMay 2013.

Sigma &

Defectsrelation

4.6 sigma means

● 4000 newborns accidently being dropped after birth per year

● 2 highly problematic landings each day on US airports

● 400 lost letters per hour at US-Post

6 sigma means

● 10 newborns accidently being dropped after birth per year

● 2 problematic landings each year on US airports.

● 1 lost letter per hour at US-Post● Watch off by 2 seconds in 31

years

Some other data

● Restaurant bills, doctors prescription writing, and payroll processing – 2.9 σ

● Average company – 3.0 σ● Airline baggage handling – 3.2 σ● Best in class companies – 5.7 σ● U.S. Navy aircraft accidents – 5.7 σ● Airline industry fatality rate – 6.2 σ

Six Sigma can be used as:

● a metric● a methodology● a management

system

As a Metric

A tool to measure process variation.

As a Methodology

● Consistent use of DMAIC-Models.● Team based problem solving.● Mesurement based Process Analysis,

Improvement and Control.

As a Management System

● Six Sigma drives strategy execution.● Leasdership, sponsorship and review.● Metrics driven governance process.● Engagement across the organization.

One of the metrics: 5S

Brainstorming

Statistical Process Control

Design of ExperimentsSpot welding schedule set up with a 3³ design.

● 3 levels for electrode pressure

● 3 levels for current

● 3 levels for time

Optimal combination is somewhere in the cube and can be found easily with dedicated software (Minitab, SAS, SPSS, Cornerstone, R-DoE.ResultTrial & Error ==> DoE:3 days ==> 4 hours.

Problem Solving

Sieve deck lifetime was 5 weeks.● Ishikawa diagram (Fishbone)● FMEA● Choise of best possible solution (Adhesive)● Experimental sieve deck manufactured● New deck followed and measured regularly

New lifetime ==> 8 months.

Yearly savings ==> 150 k€

Much more important ==> Process stabilisation

6 Sigma and Related Techniques

Warning

Thank you.

Questions ?