六西格瑪?shù)?2個(gè)步驟介紹(共25頁(yè)).ppt

1、本資料來(lái)源MethodologyOverviewPhase II: Process MeasurementPhase III: Process AnalysisPhase IV: Process ImprovementPhase V: Process ControlSix Sigma PhasesPhase I: Process DefinitionMAICDSUPPLIERProcess Step 1Processstep 2CUSTOMERProcessstep 3RECORDDEFECTSRECORD DEFECTSRECORD DEFECTSRECORDDEFECTSRECORDDEF

2、ECTSMEASURECONTROLIMPROVEANALYZECONTINUOUS IMPROVEMENT MODELPROCEDURETIMEGOALTREND CHARTACTION PLANACTIONNAMEDATEVital Few IdentificationContinuous ImprovementThe following visual illustrates how the system can workDEFINESix Sigma Breakthrough Steps DefineMeasureAnalyzeImproveControlStep 1 - Select

3、Output Characteristic - Identify Process Input/Output VariablesStep 2 - Define Performance StandardsStep 3 - Validate Measurement SystemStep 4 - Establish Process CapabilityStep 5 - Define Performance ObjectivesStep 6 - Identify Variation SourcesStep 7 - Screen Potential CausesStep 8 - Discover Vari

4、able RelationshipsStep 9 - Establish Operating TolerancesStep 10 - Validate Measurement SystemStep 11 - Determine Process CapabilityStep 12 - Implement Process ControlsSix Sigma MethodologyStep 1- Define PhaseStep 1- Define PhaseYou have to have a reason to do a project and that reason should be som

5、ething that is bothering a customer.If you cant identify what is important to work on, dont work on anything.If you cant put a name on it you cant do it.If you cant define the units of measure - be careful! You will end up having to:Define the units of measure and create a measuring system for the i

6、ssue at the beginning of your project.Step 2 - Measure PhaseStep 2 - Measure PhaseIf you dont know what makes something good or bad, how can you measure the problem in terms of defects (DPMO)?If the definition of what makes a defect (the specification) is not in the same units of measure as the sele

7、cted Y from step 1, you have the wrong spec.The definition needs to be crystal clear and briefSelect the Output Characteristic (the “Y”)What is the problem? What is a defect?Define the Performance Standard of the “Y”What is the specification or level of performancerequired by the customer?Six Sigma

8、MethodologyStep 3 - Measure PhaseStep 3 - Measure PhaseIf you cant measure something, how do you know where you are, where you have been, or where you are going?If your measurement system is incapable, STOP and FIX IT before If your measurement system is incapable, STOP and FIX IT before proceedingp

9、roceeding. Note: Measurement System Analysis (MSA) must be done on any and all defects you wish to count (watch out if you have a visual inspection of 6 characteristics)Step 4 - Measure PhaseStep 4 - Measure PhaseI know what I want to fix (step1), what defines it as good or bad (step 2), and I can a

10、ccurately measure it (step 3) so:Now I can say how my process is performing in terms of long and short term Z and DPMO which is my baseline defect rate. I know can improve from here.Validate the Measurement SystemCan we accurately and consistently measure the Y? Can you trust your data?Establish Pro

11、cess CapabilityWhat is our defect rate today?Six Sigma MethodologyStep 5 - Measure PhaseStep 5 - Measure PhaseWhere do I want to be at the end of my project? There should be a stretch goal with logic behind its selection.The objective should make it clear to all at what point the project will be con

12、sidered complete and successful.Step 6 - Analyze PhaseStep 6 - Analyze PhaseDefine Performance ObjectivesGiven the current defect rate, howmuch should we expect to improve?Identify Variation Sources ( “Xs”)What are some potential causes of the defect?List all potential inputs (KPIV, X) that could af

13、fect my output (KPOV,Y).This is filling the top of the funnel. Some tools include fishbone, C&E matrix, Failure Modes and Effects Analysis (FMEA), detailed process maps.Think outside the box - if you fix it the same way you did last year, you will have the same problem you have now.Six Sigma Met

14、hodologyStep 7- Analyze PhaseStep 7- Analyze PhaseStep 8 - Improve PhaseStep 8 - Improve PhaseScreen Potential CausesCan I figure out which of the potential causes areactually affecting my defect rate using statistical tests? Screening is done using Graphical Tools and Hypothesis Tests to identify a

15、nd prove which are the vital Xs.This is the middle of the funnel for projects with variable relationships between Xs For some simpler projects where there are no variable relationships between my Xs (or I have only 1 X) this is also step 8 the bottom of the funnel, the final vital Xs Discover Variab

16、le RelationshipsNow that I know which ones actually cause the defect, how should they be set so they produce the least amount of defects?Evaluate if any of my vital Xs are affected by other Vital Xs. This is primarily done through the use of Design of Experiment (DOE) for moderate to complex project

17、s. DOE is an experimental process that determines the impact of multiple inputs on a selected output. This leads to the bottom of the funnel, I know which Xs affect my Y and how they affect each other.Transactional - use OFAT approach.Six Sigma MethodologyStep 9 - Improve PhaseStep 9 - Improve Phase

18、Step 10 - Improve PhaseStep 10 - Improve PhaseI know which Xs are important. What range of settings can I use to make good product?In the case of a variable X (e.g. PSI on an air feed), I have to provide a setting tolerance.Establish Operating TolerancesCan I establish a tolerance for my inputs that

19、 will still yield a low defect rate to leave myself some flexibility and facilitate control?Validate Measurement SystemNow that I have improved, can I still measure the defect or the causes going forward?In the case of a variable X (e.g. PSI on an air feed), I need to validate that it can be measure

20、d (a vital X MSA).Also, I might have improved my Y so much that I can no longer “read” my process, and may have to improve my gage system to truly measure where my improvements have brought me.Six Sigma MethodologyStep 11 - Improve PhaseStep 11 - Improve PhaseStep 12 - Control PhaseStep 12 - Control

21、 PhaseDetermine Process CapabilityWhat is the defect rate now that Ihave implemented the improvements?This measures the capability of controlling my Xs where I have set them.This is also the time when we determine formal results by comparing a new capability analysis with the baseline capability ana

22、lysis (step 4) and our goals (step 5).Implement Process Controls How do we make sure it stays fixed?The Xs you have determined as vital, their settings, and other actions you have taken to make the improvement must be:Nailed downSet in concreteFully implemented (NOT just agreed to)Put into a rigorou

23、s audit scheduleBEFORE you can say a project is closed!Advanced Tools YIELD Accelerated ResultsFive Phases and Key Tools Control Plan SPC Mistake Proofing Automated Control$MeasureAnalyzeImproveControl Metrics Gage Studies Capability Process Map C & E Matrix FMEA Multi-Vari Hypothesis Testing AN

24、OVA Variation Tree DOE: Full Factorials 2K Factorials Fractional FactorialsDefine Output Characteristics Output Variables六西格瑪?shù)?2 個(gè)步驟1選擇輸出特性2定義績(jī)效標(biāo)準(zhǔn)3確定量測(cè)系統(tǒng)4確定生產(chǎn)能力5定義績(jī)效目標(biāo)6定義變化來(lái)源7篩選可能因素8發(fā)掘變量之間的關(guān)聯(lián)9定義操作公差10驗(yàn)證量測(cè)系統(tǒng)11驗(yàn)證過(guò)程生產(chǎn)能力12執(zhí)行過(guò)程控制步驟 1- 選擇輸出特性你的每一個(gè)項(xiàng)目都應(yīng)有一個(gè)開(kāi)始的理由，這個(gè)理由應(yīng)該是令你的客戶感到不方便的事情。如果你不能夠找出有什么重要的事情，那就什么也不要做

25、。如果你不能給項(xiàng)目一個(gè)執(zhí)行的理由，那就不要執(zhí)行它如果你的項(xiàng)目沒(méi)有一套績(jī)效評(píng)估的依據(jù)，或是在項(xiàng)目完成時(shí)你無(wú)法衡量完成的好壞，那你應(yīng)在項(xiàng)目開(kāi)始時(shí)就建立一套績(jī)效評(píng)估的標(biāo)準(zhǔn)。步驟 2 定義績(jī)效標(biāo)準(zhǔn)(工程標(biāo)準(zhǔn))如果你不知道什么產(chǎn)品是合格的，什么是不合格的，那你如何統(tǒng)計(jì)不良品的發(fā)生率 (DPMO)如果在工程標(biāo)準(zhǔn)中對(duì)于不合格品產(chǎn)生的原因與步驟 1中所選擇的客戶質(zhì)量統(tǒng)計(jì)中不一致，這說(shuō)明你使用了不恰當(dāng)?shù)墓こ虡?biāo)準(zhǔn)定義標(biāo)準(zhǔn)必須完全清晰簡(jiǎn)潔步驟 3 確定量測(cè)系統(tǒng)如果你不能進(jìn)行測(cè)量工作，那你怎么知道你當(dāng)前工作的進(jìn)程，你取得了什么成績(jī)，及你目前所處的位置如果你發(fā)現(xiàn)你所使用的量測(cè)系統(tǒng)存在缺陷，在繼續(xù)使用前應(yīng)馬上停止使用這套系統(tǒng)，立即改正缺陷注：MSA 應(yīng)有能力統(tǒng)計(jì)你希望統(tǒng)計(jì)的所有疵點(diǎn)數(shù)量 步驟 4 確定生產(chǎn)能力我知道我的目標(biāo)是什么 (步驟1), 判定合格或不合格的標(biāo)準(zhǔn) (步驟 2), 同時(shí)我有能力精確的測(cè)