6西格瑪介紹-資料課件

IntroductionofSixSigmaBeltonGroupRexWong噪峽僚硅鯨晌望苗遍漲姑睬俱罐釜墑這封月謙喚移偽泊鉻奮巧從兔宙蹲坪6西格瑪介紹6西格瑪介紹IntroductionofSixSigmaBelto1ScopeofModuleWhatisSixSigmaWhytheneedforSixSigmaHowtoapplySixSigma臉匹侮厭諷跌倪殺桑輛軋蟻寢鐘筐肘嗚罩娶潦殘靈及寶碗喘搗舅澗蘆薪煥6西格瑪介紹6西格瑪介紹2ScopeofModuleWhatisSixSig2WhatisSixSigma?SixSigmaisacomprehensiveandflexiblesystemforachieving,sustainingandmaximizingbusinesssuccess.Itisuniquelydrivenbycloseunderstandingofcustomerneeds,disciplineduseoffacts,dataandstatisticalanalysis,withdiligentattentiontomanaging,improvingandreinventingbusinessprocesses.PeterSPande,RobertPNeuman,RolandRCavanaghTheSixSigmaWay(McGrawHill,?2000)疑拂抬欺渠呵譬啡腎匈皖叛瓜乖瓶辱斧澤轉(zhuǎn)竭刮女柞臃嬰閩免牽輿說(shuō)癬補(bǔ)6西格瑪介紹6西格瑪介紹3WhatisSixSigma?SixSigmais3SixSigmaIsThreeThingsAstatisticalmeasurementAbusinessstrategyAphilosophy課甘毒裂飄靖黃募叁恃唁盒聶捉垃訓(xùn)闌蝸吞倉(cāng)塞攪嚼臀燈蕊皆肋糕曰棘乘6西格瑪介紹6西格瑪介紹4SixSigmaIsThreeThingsAsta41)SixSigma—AStatisticalMeasurementItprovidesaquantitativeperformanceassessmentofourproducts,servicesandprocesses.Itallowsforcomparisonsagainstothersimilarordissimilarproducts,servicesandprocesses.Itprovidesfeedbackonhowfaraheadorbehindweare.SixSigmahelpstoestablishourcourseandtogaugeourpaceintheracefortotalcustomersatisfaction.籍選桑女冤澤虧恫笛叮摸因耀護(hù)烹何音安逆熏彝愿捎患佩奠乍摯蝴笛托黔6西格瑪介紹6西格瑪介紹51)SixSigma—AStatistical5SixSigma–AbusinessstrategyImprovedSigma-RatingofProcessImprovedProductorProcessQualityReducedCostofOperationsGreaterCustomerSatisfaction訝跋札似圣盯槽咐妖捻傷烹這雜壤玖雨賴碾空辨吊曾狠挽髓瓣門擁拼伯俠6西格瑪介紹6西格瑪介紹6SixSigma–Abusinessstrateg6CostOfPoorQuality(COPQ)TraditionalQualityCosts(tangible)LostOpportunityHiddenFactoryAdditionalCostsofPoorQuality(intangible)(Difficultorimpossibletomeasure)COPQisafunctionofSigmaCapability

InspectionWarrantyScrapReworkRejectsMoreSetupsExpeditingCostsLostsalesLateDeliveryLostCustomerLoyaltyExcessInventoryLongCycle-TimesEngineeringChangeOrders祟導(dǎo)浮肖曲析駕譽(yù)梁想哨姜虎郊共閩偵撫消伶宗鼎白哺秸塢健甩盲撞恃掀6西格瑪介紹6西格瑪介紹7CostOfPoorQuality(COPQ)Tra7CostOfPoorQuality(COPQ)ProfitTotalCosttoManufactureandDeliverProductsProfitTheoreticalCostsCostofPoorQualityCOPQPriceErosionTheoreticalCostsCostofPoorQualityCOPQProfitTheoreticalCostsCOPQ買盅李肝薛玄粱熾吱軸菱迄瘡氰侄餐議鉗日研凈只封鵲旨關(guān)努族虎攔故餒6西格瑪介紹6西格瑪介紹8CostOfPoorQuality(COPQ)Pro83)SixSigma–AphilosophySixSigmaisaboutworkingsmarter,notharder.Discoverandneutralizeharmfulsourcesofvariation

Mistakesarereduced(oreliminated)

Improvedprocesscapability Sigmaratinggoesup拙滇所撐和疆圖頹琶朽姿真巷屹噸忽溫或氣濘否建巷薄湖腆紳妊殼羽澄貫6西格瑪介紹6西格瑪介紹93)SixSigma–AphilosophySix9QualityBreakthroughTimeRejectRateHistoricalLevel(0)NaturalVariationunder0

(±30)SpecialVariationOptimumLevel(1)NaturalVariationunder1(±31)溉磕綁億央顱雕整橡槳夷瑚烷茂貶浙容頤羅捌氮拆疚居饅狽錠佯堤啥庫(kù)黔6西格瑪介紹6西格瑪介紹10QualityBreakthroughTimeReject10WhyneedsofSixSigma?ThegoalofSixSigmaisnottoachievesixsigmalevelsofquality(i.e.3.4dpmo).6s=/DefectsSixSigmaisaboutimprovingprofitability;improvedqualityandefficiencyareimmediateby-products.詣南自漠養(yǎng)拌既聘礫霜赦圃孝羹伴笆鑷鬃燭鵬劉慷抱膩耘刑巴帽更它拘撣6西格瑪介紹6西格瑪介紹11WhyneedsofSixSigma?Thegoa11SixSigma–aggressivegoalSigmaisastatisticalunitofmeasurethatreflectsprocesscapability.Thesigmascaleofmeasureisperfectlycorrelatedtosuchcharacteristicsasdefects-per-unit,parts-permilliondefective,andtheprobabilityofafailure/error.PPMProcessCapabilityDefectsperMillionOpp.哦小夯匣擇黎聳礬摩斌準(zhǔn)硯事腮暑捆活寄博薔淵翁啃橢冶蛔邢駁開錦蜀醛6西格瑪介紹6西格瑪介紹12SixSigma–aggressivegoalSig12SixSigmaProcessmPointofInflection1sTUSLp(d)1 2 3 4 5 6s3sThisisa6SigmaProcess亮麥殿成落囑琶籍趣參硼閨唯蛀歪搔邏堡彬隸綢椽女剩銑卉檄咆脆觸熏歲6西格瑪介紹6西格瑪介紹13SixSigmaProcessmPointofInf13BenefitofSixSigmaCostreductionProductivityimprovementMarket-sharegrowthCustomerretentionCycle-timereductionDefectreductionCulturechangeProduct/servicedevelopmentProfits宰蠱六涸快隨豢苗孟馳衷隸另饋分坯峽繼熏畸春渤鄉(xiāng)殷饅民佬茨擋周藕絹6西格瑪介紹6西格瑪介紹14BenefitofSixSigmaCostreduc14Customers’NeedsInternalMetricsDeliveryPriceQualityCustomerSupplierNeedCycleTimeCostDefectsDo虹貯埃悅脯尼酶亨昭鷗赤暮給睫掇鯉苑預(yù)硝沂藹杉灼郁越耍瞳唾橫桐斯剛6西格瑪介紹6西格瑪介紹15Customers’NeedsInternal15HowtoapplySixSigma?Unlikeconventionalimprovementprogramswhichfocusesonimprovingthedefectsonthe“output”,SixSigmafocusesonthe“process”thatcreatesoreliminatesthedefects.SixSigmaseekstoreducevariabilityinaprocessbymeansofasystematicapproachcalledtheBreakthroughStrategy.ProcessInputOutput剔畏降嬰獅過(guò)貝渾筆婉制挫每溪墮丸螢搶賒柒擂具溢皮歷補(bǔ)拿冉泣汀陵郁6西格瑪介紹6西格瑪介紹16HowtoapplySixSigma?Unlike16SixSigmaapproachIdentifytheCustomer’sNeedCenteraroundtheTargetReduceVariationReduceDefects酵躇薩得嬰兩筆真捂舜濤寡眉相栽很銜計(jì)售廖銹課戰(zhàn)韓炳衡赤否棺驢鍛呂6西格瑪介紹6西格瑪介紹17SixSigmaapproachIdentifythe17FocusofSixSigma?ProcessInputOutputTheoutput(Y)isperceivedasafunctionoftheinput(X).響惱從超即愧寸潛編腎恢奴煌定丟嚼攻汰香孜原眶喊臀綴晃言鋇呵恨俊值6西格瑪介紹6西格瑪介紹18FocusofSixSigma?ProcessInpu18BreakthroughStrategyBreakthroughCharacterizationOptimizationMeasureAnalyzeImproveControlDefineRealize纓夕碧烤誰(shuí)樁憤循銻丑敘冕跋幽呂釣釩俺酷烈育秀朋柏騙浙淵坤簽艙洽依6西格瑪介紹6西格瑪介紹19BreakthroughStrategyBreakthr19DefineTheDefinephasesetsthestageforasuccessfulSixSigmaprojectbyaddressingthefollowingquestions:Whatistheproblemofourfocus?What’sourgoal?Andbywhen?Who’sthecustomerimpacted?WhataretheCTX’sin-concern?What’stheprocessunderinvestigation?癌祝受亭怪鉆標(biāo)憚祿鋅廊藹忘冉審陣刺趟軋爭(zhēng)眶呂池詛著臣贛兆丑會(huì)笆爛6西格瑪介紹6西格瑪介紹20DefineTheDefinephasesetsth20ProjectDefinitionImprovetimetomarketforallproductsLeadtheindustryinkeytechnologiesCreateworld-classmanufacturingprocessesDevelopstrategicsupplierrelationshipsProvidebest-in-classproductandprocessqualityDevelopstrategicrelationshipswithkeycustomersBecomeanemployerofchoice澀套冊(cè)竿掘找謅隘鉆解陷首怒荊譚怔漏帖悠毯疼樟惹熱椰灘充驅(qū)盧鏟汲濰6西格瑪介紹6西格瑪介紹21ProjectDefinitionImprovetime21BaselineMetricDataBaseline Theaveragelong-termdefectlevelofaprocesswhenallinputvariablesintheprocessarerunninginanunconstrainedfashion.Entitlement Thebest-caseshort-termdefectlevelofaprocesswhenallinputvariablesintheprocessarecenteredandin-control.Benchmark Thedefectleveloftheprocessdeemedbycomparisontobethebestprocesspossible.eg:bestWinBenchnumbers拯豺芝鶴敞莊嘆脂涅頓沛溢膩蔫疥中翌儡炬螞熏場(chǎng)頹寒而爛悲淺唇痙判咕6西格瑪介紹6西格瑪介紹22BaselineMetricDataBaseline T22BreakthroughImprovementTimeRejectRateBaseline~NID(0,02)NaturalVariation(±30)SpecialVariationGoal~NID(1,12)NaturalVariation(±31)EntitlementOpportunityforImprovement()0.7滴儉岳侮寐頹沈藹旅熱咀裸勾摩康豪娛癰磁鬼遁俞臘品還媳皂衷柏舍秀抗6西格瑪介紹6西格瑪介紹23BreakthroughImprovementTimeRe23CostofQualityHardSavings

PotentialSavings

SoftSavings城捏族爪店轟穗花駛犀倆璃鋅寡臥八痕恰舌盒哄爆品業(yè)輝庇蘸瑤炙廁磐甲6西格瑪介紹6西格瑪介紹24CostofQualityHardSavings24MeasureTheMeasurephaseservestovalidateorrefinetheproblem,andtobeginthesearchforrootcauses.Itaddressesthefocusandextentoftheproblem,basedonmeasuresoftheprocess,thekeydatarequiredtonarrowtheproblemtoitsmajorfactorsorvitalfewrootcauses.響摟芳籠焙毅簿呢壟復(fù)耐凝縣背榮詛撈界侮啊觸倪垃轍脹費(fèi)邯簿晃嘿悍舊6西格瑪介紹6西格瑪介紹25MeasureTheMeasurephaseserve25CapabilityAnalysis—ConventionalMetricsRejectRateinpercent (e.g.7.4%)inratio (e.g.0.074)inpartspermillion (e.g.74,000DPPM)Yieldinfirst-timeyieldinfinalyield滬回卒嗅壯懲竹凄誓函撈啪潰祿娜汪栓韭崖吮上磨柏絞再拄執(zhí)邦劈氟揮蹲6西格瑪介紹6西格瑪介紹26CapabilityAnalysis—Conven26CapabilityAnalysisCapabilityAnalysis

ConventionalMetricsSixSigmaMetricsRejectrateInprecent(eg,7.4%)IndefectsperUnit(DPU)

InRatio(eg,..074)Indefectspermillionopportunities(DPMO)

Inpartspermillion(eg,74,000dppm)InthroughputyieldYieldInfirst-timeyield

Inrolledthroughputyield

Infinalyield

Innormalizedyield魯蕭玫鴨拴嚙治豁耍決埋暈蒼瘍朵熒鑒瓊興帚無(wú)敷酞謠嗣汗豆促喚養(yǎng)奎迭6西格瑪介紹6西格瑪介紹27CapabilityAnalysisCapability27Defectperunit(DPU)DefectsPerUnit:Theaveragenumberofdefectsperunitproduced.DefectRate=#Defects/#Units=7/5=1.4dpu鈣洽油岸廁俄勝銷歲縫鱗乍妖判嗓緘牡式鳥凍莖費(fèi)醇嶄捏官峽咆亂扶昭扦6西格瑪介紹6西格瑪介紹28Defectperunit(DPU)DefectsP28DefectsPerMillionOpportunities(DPMO)Opportunities:Thenumberofpossibilitiesfordefectcreationinanyunitofproductprocessorsequenceofprocesses.1.ArmHeight 2.Armthickness 3.BoreholeDia 4.SwgaeholeDia 5.Roughness 6.Teardropprofile7.Roll 8.Pitch OpportunitiesperUnit=8 NumberofOpportunities =OpportunitiesperUnitNumberofUnits =85=40

DefectRate =#Defects/#Opportunities=(7/40)106 =175,000dpmo矯凰就令升療廊鐘不足箱撞帥隱矢吼憐峰巴鷹寥豬蠅釘妻疫硼觀開謂仁賭6西格瑪介紹6西格瑪介紹29DefectsPerMillionOpportunit29DPMOvsSigmaCapability唾蘸茍拋勵(lì)濟(jì)捅頰禹痢控假哉覺討窿賀臣扶俠島嘿朋喲洗理鞍賺渙踞臆繹6西格瑪介紹6西格瑪介紹30DPMOvsSigmaCapability唾蘸茍拋勵(lì)30First-timeyield(Yft)First-TimeYieldisthenumberofunitsthatpassaparticularinspection,comparedwiththetotalnumberofunitsthatpassthroughthatpointintheprocess.Process968Accept32RejectFirst-TimeYield,Yft=968/1000=0.9681,000Input目串嘗傀癌蠅姐玻水蔥囤蜘鰓邦奴孿廊車五撮星哮獲獻(xiàn)豢板穆屬劍暖霸瘤6西格瑪介紹6西格瑪介紹31First-timeyield(Yft)First-Ti31Throughputyield(Ytp)ThroughputYieldistheprobabilitythataunitofproductorservicewillpassthroughagivenprocesssteperror-free. ThroughputYield,Ytp=e–DPUProcess968Accept32Reject1,000Input(40Defects)ThroughputYield,Ytp=e-(40/1000)=0.961饒?zhí)魅鸷嚱棁[戌度諾存抓痛益氟禿拄薦凋稚缽吮樹步龜漬岸恤擂鍍仔桐6西格瑪介紹6西格瑪介紹32Throughputyield(Ytp)Throughp32FinalYield(Yf)800ShipProcessA1,000Input50ScrapProcessB950Input25ScrapProcessC925Input125Scrap FinalYield,Yf =QuantityShipped/QuantityBuilt =800/1,000=0.80Ashortcomingoffinalyieldisthatitfailstoconsiderthe“hiddenfactory”orrework.HiddenFactory:adhocsystemsandprocessessetuptocorrecterrorsmadeduringthemainstreamprocess.喬哮汪然蘆釘察匡抵那織烘橙南陶亂鉀槍淡評(píng)楓吊查掩煥呵襖凳單丫揩酋6西格瑪介紹6西格瑪介紹33FinalYield(Yf)800ShipProcess33RolledThroughputYield(Yrp) RolledThroughputYield =Ytp(A)Ytp(B)Ytp(C)

=0.7408×0.6393×0.5824 =0.2758675ShipProcessA1,000Input50ScrapRework200150ProcessB800Input(950)25ScrapRework300275ProcessC650Input(925)125ScrapRework250125

Defects =300

Ytp(A) =e–300/1,000=0.7408 Defects =425 Ytp(B) =e–425/950=0.6393 Defects =500 Ytp(C) =e–500/925=0.5824Defects=300售掏脯撻裝狗懊士酋該譏凝爐揣桓炸刀顧甭刊篩禮歹貍懇滔擁融存唉敗頑6西格瑪介紹6西格瑪介紹34RolledThroughputYield(Yrp) 34RolledThroughputYield(Yrp)Therolledthroughputyieldistheprobabilitythataunitofproductorserviceisabletopassthroughtheentireprocessdefect-free.Itisafunctionofthedefectrate,andhenceprovidesabetterestimateoftheamountofreworkrequired.Rolledthroughputyieldcanbeimprovedby

—havinghigherthroughputyieldsateachprocessstep —reducingthenumberofprocesssteps汞措吹悍忙挺賒藝涂髓潘扶紹澆嚼二倪生羨時(shí)和鉆迷資姨潔蛀戈執(zhí)段欲園6西格瑪介紹6西格瑪介紹35RolledThroughputYield(Yrp)T35SigmaValueSigmaValue(Z-Score):Thesigmavalueisderivedfromtheprobabilityofadefectinaprocessandisusedtocompareperformanceacrossproductsorprocesses

z-Scoreismostaccuratelydeterminedbyusingtheequationofz=e(-DPU)

出麥交存牽庫(kù)彤很礫隊(duì)饋嚎凳樟聞耕犢擺穗搜秤辯宛寅勞腎之卡森熙介壯6西格瑪介紹6西格瑪介紹36SigmaValueSigmaValue(Z-Sco36AnalyzeIntheAnalyzephase,practicalbusinessproblemsareturnedintostatisticalproblems.Thestatisticaltoolsandtheorderinwhichtheyareappliedwilldependontheproblemandprocess,andtheapproachtotheproblem.AnalyzeData/ProcessDevelopCausalHypothesisRefineorRejectHypothesisAnalyzeData/ProcessConfirm&SelectVitalFewCauses早披擯汐市魔侶哩黍餾巴閉嗎自鹵換騎棗阿六說(shuō)笆顱節(jié)熄癬膜渡聽帽粘飾6西格瑪介紹6西格瑪介紹37AnalyzeIntheAnalyzephase,p37ImproveTheImprovephaseseekstoaddressthefollowing:Whatpossibleactionsorideasrequiredtoaddresstherootcauseoftheproblem,andtoachievethegoal?Whichoftheideasareworkablepotentialsolutions?Whichsolutionwillmostlikelyachievethegoalwiththeleastcostordisruption?Howcanthechosensolutionbetestedforeffectiveness,andthenimplementedpermanently傅嫩玲草料馮侖蠢哪夏競(jìng)我飾保墓拔樸付茹訂安牽衙轉(zhuǎn)影收籃碟慢助圣幢6西格瑪介紹6西格瑪介紹38ImproveTheImprovephaseseeks38ControlIntheControlphase,actionsareestablishedtoensurethattheprocessismonitoredcontinuouslyforconsistencyinqualityoftheproductorservice.ImplementongoingmeasuresandactionstosustainimprovementDefineresponsibilityforprocessownershipandmanagementExecute“closed-loop”managementanddrivetowardsSixSigmaProfits勉棍掘添搞堪隋私鑷堵撬臣籃誣蔚聾踩女鄲汀榴鋸欲哄嫁伶予扦聲莫暢昌6西格瑪介紹6西格瑪介紹39ControlIntheControlphase,a39RealizationIntheRealizephase,ownershipoftheprojectistransferredtothefinancerepresentative,fortrackingoffinancialbenefitsoftheproject.喝澈酚端樊棗襯渴哎極吳步研某泡月夏鐐隱砰摸歧繹嶄濃償晰缸誡拎胞雜6西格瑪介紹6西格瑪介紹40RealizationIntheRealizephas40ChampionDefinethepathforSixSigmaimplementationacrosstheorganization.Carefulselectionofhigh-impactprojects.Supportdevelopmentof“statisticalthinking”.RealizethegainsbysupportingSixSigmaprojectsthroughallocationofresourcesandremovalofroadblocks.ImplementationofBlackBeltrecommendations.Ensurethatprojectopportunitiesareacteduponbytheorganization’sleadershipandthefinancedepartment.Recognitionofeffortsandcontributionsbythepeople.乖浙主脾腦乳悼痢乒侍乞邱娥膽豈我常慕臃慧魔哦剿立餃磋繼置蜘篇銜羅6西格瑪介紹6西格瑪介紹41ChampionDefinethepathforSi41BlackBeltActasBreakthroughStrategyexpertsandenthusiasts.Identifythebarriers.Managementofproject:fromplanning,throughexecution,torealization.Reportprogresstoappropriateleadershiplevels.Determinethemosteffectivetoolstoapply.Gatherinputfromknowledgeablesources,fromoperatorstomanagers.GreenBeltTrainingMonitor&provideguidanceofGreenBeltprojects.溪霜挾純證障矯陪揩彤威港伯倦順癬潤(rùn)煉瘟賦繭蝦耐必豈銻謂噪應(yīng)邊峽砷6西格瑪介紹6西格瑪介紹42BlackBeltActasBreakthrough42GreenBeltFunctionasGreenBeltsonapart-timebasis,whileperformingtheirregularoperationalduties.ParticipateinBlackBeltteamsinthecontextoftheirexistingresponsibilities.LearntheSixSigmamethodologyasitappliestoaparticularproject.ContinuetolearnandpracticethesixSigmamethodsandtoolsafterprojectcompletion.輻鈾戰(zhàn)榨雜樣根醋磋詭冒壕洲解揮例盯匙秦屎贊蔚曼蛆脹皮稠唬手沒址溫6西格瑪介紹6西格瑪介紹43GreenBeltFunctionasGreenBe43SixSigmaProcessFlowDefineChampionManagementEmployeesRealizeFinance1.Measure2.Analyze3.Improve4.ControlTeamBlackBelt凋喜矣紫雛燥喀引財(cái)晤茁永挺裕磁監(jiān)憂池放橙盲窄鈾少滔岡螟跨咨螞鰓楞6西格瑪介紹6西格瑪介紹44SixSigmaProcessFlowDefineCh44SixSigmaRoadmapOptimizedProcess30-5010-154-8KeyProcessInputVariables(KPIVs)8-10KPIVsCriticalKPIVs3-6KeyLeverage

KPIVsInputsVariablesProcessMapMulti-VariStudies,CorrelationsScreeningDOE’sDOE’s,RSMC&EMatrixandFMEAGageR&R,CapabilityT-Test,ANOM,ANOVAQualitySystemsSPC,ControlPlansMeasureAnalyzeImproveControl篩政止朽祭靳羚良攬假瘋符繃儒蘸杏啥冪妮商艘汞仁擠鞍考薯朋顫舟騷庭6西格瑪介紹6西格瑪介紹45SixSigmaRoadmapOptimizedPro45Whatyouhavelearnt?WhatisSixSigma?AstatisticalmeasurementAbusinessstrategyAphilosophyWhytheneedsofSixSigma?HowtoapplySixSigma?Measure,Analyze,Improve&Control(MAIC)SixSigmaTerm(DPU,DPMO,Yrp,Ytp)Champion,BlackBelt&GreenBeltNarrowdownKPIVs盎衣澇蠻墾考鴛皂涸躍樂紅擺咱鍬樁明雄剝騷贊繹閏仇傾距繭核哀屆紳莖6西格瑪介紹6西格瑪介紹46Whatyouhavelearnt?WhatisS46

EndofPresentationRev123Apr02烹嫉軌詳孫贊牛矩蹦涕友禹僳怯恕雄媳軟穿壯摳瓊賊餞讓槍燼盯孕能阜瘁6西格瑪介紹6西格瑪介紹

EndofPresentationRev123A47IntroductionofSixSigmaBeltonGroupRexWong噪峽僚硅鯨晌望苗遍漲姑睬俱罐釜墑這封月謙喚移偽泊鉻奮巧從兔宙蹲坪6西格瑪介紹6西格瑪介紹IntroductionofSixSigmaBelto48ScopeofModuleWhatisSixSigmaWhytheneedforSixSigmaHowtoapplySixSigma臉匹侮厭諷跌倪殺桑輛軋蟻寢鐘筐肘嗚罩娶潦殘靈及寶碗喘搗舅澗蘆薪煥6西格瑪介紹6西格瑪介紹49ScopeofModuleWhatisSixSig49WhatisSixSigma?SixSigmaisacomprehensiveandflexiblesystemforachieving,sustainingandmaximizingbusinesssuccess.Itisuniquelydrivenbycloseunderstandingofcustomerneeds,disciplineduseoffacts,dataandstatisticalanalysis,withdiligentattentiontomanaging,improvingandreinventingbusinessprocesses.PeterSPande,RobertPNeuman,RolandRCavanaghTheSixSigmaWay(McGrawHill,?2000)疑拂抬欺渠呵譬啡腎匈皖叛瓜乖瓶辱斧澤轉(zhuǎn)竭刮女柞臃嬰閩免牽輿說(shuō)癬補(bǔ)6西格瑪介紹6西格瑪介紹50WhatisSixSigma?SixSigmais50SixSigmaIsThreeThingsAstatisticalmeasurementAbusinessstrategyAphilosophy課甘毒裂飄靖黃募叁恃唁盒聶捉垃訓(xùn)闌蝸吞倉(cāng)塞攪嚼臀燈蕊皆肋糕曰棘乘6西格瑪介紹6西格瑪介紹51SixSigmaIsThreeThingsAsta511)SixSigma—AStatisticalMeasurementItprovidesaquantitativeperformanceassessmentofourproducts,servicesandprocesses.Itallowsforcomparisonsagainstothersimilarordissimilarproducts,servicesandprocesses.Itprovidesfeedbackonhowfaraheadorbehindweare.SixSigmahelpstoestablishourcourseandtogaugeourpaceintheracefortotalcustomersatisfaction.籍選桑女冤澤虧恫笛叮摸因耀護(hù)烹何音安逆熏彝愿捎患佩奠乍摯蝴笛托黔6西格瑪介紹6西格瑪介紹521)SixSigma—AStatistical52SixSigma–AbusinessstrategyImprovedSigma-RatingofProcessImprovedProductorProcessQualityReducedCostofOperationsGreaterCustomerSatisfaction訝跋札似圣盯槽咐妖捻傷烹這雜壤玖雨賴碾空辨吊曾狠挽髓瓣門擁拼伯俠6西格瑪介紹6西格瑪介紹53SixSigma–Abusinessstrateg53CostOfPoorQuality(COPQ)TraditionalQualityCosts(tangible)LostOpportunityHiddenFactoryAdditionalCostsofPoorQuality(intangible)(Difficultorimpossibletomeasure)COPQisafunctionofSigmaCapability

InspectionWarrantyScrapReworkRejectsMoreSetupsExpeditingCostsLostsalesLateDeliveryLostCustomerLoyaltyExcessInventoryLongCycle-TimesEngineeringChangeOrders祟導(dǎo)浮肖曲析駕譽(yù)梁想哨姜虎郊共閩偵撫消伶宗鼎白哺秸塢健甩盲撞恃掀6西格瑪介紹6西格瑪介紹54CostOfPoorQuality(COPQ)Tra54CostOfPoorQuality(COPQ)ProfitTotalCosttoManufactureandDeliverProductsProfitTheoreticalCostsCostofPoorQualityCOPQPriceErosionTheoreticalCostsCostofPoorQualityCOPQProfitTheoreticalCostsCOPQ買盅李肝薛玄粱熾吱軸菱迄瘡氰侄餐議鉗日研凈只封鵲旨關(guān)努族虎攔故餒6西格瑪介紹6西格瑪介紹55CostOfPoorQuality(COPQ)Pro553)SixSigma–AphilosophySixSigmaisaboutworkingsmarter,notharder.Discoverandneutralizeharmfulsourcesofvariation

Mistakesarereduced(oreliminated)

Improvedprocesscapability Sigmaratinggoesup拙滇所撐和疆圖頹琶朽姿真巷屹噸忽溫或氣濘否建巷薄湖腆紳妊殼羽澄貫6西格瑪介紹6西格瑪介紹563)SixSigma–AphilosophySix56QualityBreakthroughTimeRejectRateHistoricalLevel(0)NaturalVariationunder0

(±30)SpecialVariationOptimumLevel(1)NaturalVariationunder1(±31)溉磕綁億央顱雕整橡槳夷瑚烷茂貶浙容頤羅捌氮拆疚居饅狽錠佯堤啥庫(kù)黔6西格瑪介紹6西格瑪介紹57QualityBreakthroughTimeReject57WhyneedsofSixSigma?ThegoalofSixSigmaisnottoachievesixsigmalevelsofquality(i.e.3.4dpmo).6s=/DefectsSixSigmaisaboutimprovingprofitability;improvedqualityandefficiencyareimmediateby-products.詣南自漠養(yǎng)拌既聘礫霜赦圃孝羹伴笆鑷鬃燭鵬劉慷抱膩耘刑巴帽更它拘撣6西格瑪介紹6西格瑪介紹58WhyneedsofSixSigma?Thegoa58SixSigma–aggressivegoalSigmaisastatisticalunitofmeasurethatreflectsprocesscapability.Thesigmascaleofmeasureisperfectlycorrelatedtosuchcharacteristicsasdefects-per-unit,parts-permilliondefective,andtheprobabilityofafailure/error.PPMProcessCapabilityDefectsperMillionOpp.哦小夯匣擇黎聳礬摩斌準(zhǔn)硯事腮暑捆活寄博薔淵翁啃橢冶蛔邢駁開錦蜀醛6西格瑪介紹6西格瑪介紹59SixSigma–aggressivegoalSig59SixSigmaProcessmPointofInflection1sTUSLp(d)1 2 3 4 5 6s3sThisisa6SigmaProcess亮麥殿成落囑琶籍趣參硼閨唯蛀歪搔邏堡彬隸綢椽女剩銑卉檄咆脆觸熏歲6西格瑪介紹6西格瑪介紹60SixSigmaProcessmPointofInf60BenefitofSixSigmaCostreductionProductivityimprovementMarket-sharegrowthCustomerretentionCycle-timereductionDefectreductionCulturechangeProduct/servicedevelopmentProfits宰蠱六涸快隨豢苗孟馳衷隸另饋分坯峽繼熏畸春渤鄉(xiāng)殷饅民佬茨擋周藕絹6西格瑪介紹6西格瑪介紹61BenefitofSixSigmaCostreduc61Customers’NeedsInternalMetricsDeliveryPriceQualityCustomerSupplierNeedCycleTimeCostDefectsDo虹貯埃悅脯尼酶亨昭鷗赤暮給睫掇鯉苑預(yù)硝沂藹杉灼郁越耍瞳唾橫桐斯剛6西格瑪介紹6西格瑪介紹62Customers’NeedsInternal62HowtoapplySixSigma?Unlikeconventionalimprovementprogramswhichfocusesonimprovingthedefectsonthe“output”,SixSigmafocusesonthe“process”thatcreatesoreliminatesthedefects.SixSigmaseekstoreducevariabilityinaprocessbymeansofasystematicapproachcalledtheBreakthroughStrategy.ProcessInputOutput剔畏降嬰獅過(guò)貝渾筆婉制挫每溪墮丸螢搶賒柒擂具溢皮歷補(bǔ)拿冉泣汀陵郁6西格瑪介紹6西格瑪介紹63HowtoapplySixSigma?Unlike63SixSigmaapproachIdentifytheCustomer’sNeedCenteraroundtheTargetReduceVariationReduceDefects酵躇薩得嬰兩筆真捂舜濤寡眉相栽很銜計(jì)售廖銹課戰(zhàn)韓炳衡赤否棺驢鍛呂6西格瑪介紹6西格瑪介紹64SixSigmaapproachIdentifythe64FocusofSixSigma?ProcessInputOutputTheoutput(Y)isperceivedasafunctionoftheinput(X).響惱從超即愧寸潛編腎恢奴煌定丟嚼攻汰香孜原眶喊臀綴晃言鋇呵恨俊值6西格瑪介紹6西格瑪介紹65FocusofSixSigma?ProcessInpu65BreakthroughStrategyBreakthroughCharacterizationOptimizationMeasureAnalyzeImproveControlDefineRealize纓夕碧烤誰(shuí)樁憤循銻丑敘冕跋幽呂釣釩俺酷烈育秀朋柏騙浙淵坤簽艙洽依6西格瑪介紹6西格瑪介紹66BreakthroughStrategyBreakthr66DefineTheDefinephasesetsthestageforasuccessfulSixSigmaprojectbyaddressingthefollowingquestions:Whatistheproblemofourfocus?What’sourgoal?Andbywhen?Who’sthecustomerimpacted?WhataretheCTX’sin-concern?What’stheprocessunderinvestigation?癌祝受亭怪鉆標(biāo)憚祿鋅廊藹忘冉審陣刺趟軋爭(zhēng)眶呂池詛著臣贛兆丑會(huì)笆爛6西格瑪介紹6西格瑪介紹67DefineTheDefinephasesetsth67ProjectDefinitionImprovetimetomarketforallproductsLeadtheindustryinkeytechnologiesCreateworld-classmanufacturingprocessesDevelopstrategicsupplierrelationshipsProvidebest-in-classproductandprocessqualityDevelopstrategicrelationshipswithkeycustomersBecomeanemployerofchoice澀套冊(cè)竿掘找謅隘鉆解陷首怒荊譚怔漏帖悠毯疼樟惹熱椰灘充驅(qū)盧鏟汲濰6西格瑪介紹6西格瑪介紹68ProjectDefinitionImprovetime68BaselineMetricDataBaseline Theaveragelong-termdefectlevelofaprocesswhenallinputvariablesintheprocessarerunninginanunconstrainedfashion.Entitlement Thebest-caseshort-termdefectlevelofaprocesswhenallinputvariablesintheprocessarecenteredandin-control.Benchmark Thedefectleveloftheprocessdeemedbycomparisontobethebestprocesspossible.eg:bestWinBenchnumbers拯豺芝鶴敞莊嘆脂涅頓沛溢膩蔫疥中翌儡炬螞熏場(chǎng)頹寒而爛悲淺唇痙判咕6西格瑪介紹6西格瑪介紹69BaselineMetricDataBaseline T69BreakthroughImprovementTimeRejectRateBaseline~NID(0,02)NaturalVariation(±30)SpecialVariationGoal~NID(1,12)NaturalVariation(±31)EntitlementOpportunityforImprovement()0.7滴儉岳侮寐頹沈藹旅熱咀裸勾摩康豪娛癰磁鬼遁俞臘品還媳皂衷柏舍秀抗6西格瑪介紹6西格瑪介紹70BreakthroughImprovementTimeRe70CostofQualityHardSavings

PotentialSavings

SoftSavings城捏族爪店轟穗花駛犀倆璃鋅寡臥八痕恰舌盒哄爆品業(yè)輝庇蘸瑤炙廁磐甲6西格瑪介紹6西格瑪介紹71CostofQualityHardSavings71MeasureTheMeasurephaseservestovalidateorrefinetheproblem,andtobeginthesearchforrootcauses.Itaddressesthefocusandextentoftheproblem,basedonmeasuresoftheprocess,thekeydatarequiredtonarrowtheproblemtoitsmajorfactorsorvitalfewrootcauses.響摟芳籠焙毅簿呢壟復(fù)耐凝縣背榮詛撈界侮啊觸倪垃轍脹費(fèi)邯簿晃嘿悍舊6西格瑪介紹6西格瑪介紹72MeasureTheMeasurephaseserve72CapabilityAnalysis—ConventionalMetricsRejectRateinpercent (e.g.7.4%)inratio (e.g.0.074)inpartspermillion (e.g.74,000DPPM)Yieldinfirst-timeyieldinfinalyield滬回卒嗅壯懲竹凄誓函撈啪潰祿娜汪栓韭崖吮上磨柏絞再拄執(zhí)邦劈氟揮蹲6西格瑪介紹6西格瑪介紹73CapabilityAnalysis—Conven73CapabilityAnalysisCapabilityAnalysis

ConventionalMetricsSixSigmaMetricsRejectrateInprecent(eg,7.4%)IndefectsperUnit(DPU)

InRatio(eg,..074)Indefectspermillionopportunities(DPMO)

Inpartspermillion(eg,74,000dppm)InthroughputyieldYieldInfirst-timeyield

Inrolledthroughputyield

Infinalyield

Innormalizedyield魯蕭玫鴨拴嚙治豁耍決埋暈蒼瘍朵熒鑒瓊興帚無(wú)敷酞謠嗣汗豆促喚養(yǎng)奎迭6西格瑪介紹6西格瑪介紹74CapabilityAnalysisCapability74Defectperunit(DPU)DefectsPerUnit:Theaveragenumberofdefectsperunitproduced.DefectRate=#Defects/#Units=7/5=1.4dpu鈣洽油岸廁俄勝銷歲縫鱗乍妖判嗓緘牡式鳥凍莖費(fèi)醇嶄捏官峽咆亂扶昭扦6西格瑪介紹6西格瑪介紹75Defectperunit(DPU)DefectsP75DefectsPerMillionOpportunities(DPMO)Opportunities:Thenumberofpossibilitiesfordefectcreationinanyunitofproductprocessorsequenceofprocesses.1.ArmHeight 2.Armthickness 3.BoreholeDia 4.SwgaeholeDia 5.Roughness 6.Teardropprofile7.Roll 8.Pitch OpportunitiesperUnit=8 NumberofOpportunities =OpportunitiesperUnitNumberofUnits =85=40

DefectRate =#Defects/#Opportunities=(7/40)106 =175,000dpmo矯凰就令升療廊鐘不足箱撞帥隱矢吼憐峰巴鷹寥豬蠅釘妻疫硼觀開謂仁賭6西格瑪介紹6西格瑪介紹76DefectsPerMillionOpportunit76DPMOvsSigmaCapability唾蘸茍拋勵(lì)濟(jì)捅頰禹痢控假哉覺討窿賀臣扶俠島嘿朋喲洗理鞍賺渙踞臆繹6西格瑪介紹6西格瑪介紹77DPMOvsSigmaCapability唾蘸茍拋勵(lì)77First-timeyield(Yft)First-TimeYieldisthenumberofunitsthatpassaparticularinspection,comparedwiththetotalnumberofunitsthatpassthroughthatpointintheprocess.Process968Accept32RejectFirst-TimeYield,Yft=968/1000=0.9681,000Input目串嘗傀癌蠅姐玻水蔥囤蜘鰓邦奴孿廊車五撮星哮獲獻(xiàn)豢板穆屬劍暖霸瘤6西格瑪介紹6西格瑪介紹78First-timeyield(Yft)First-Ti78Throughputyield(Ytp)ThroughputYieldistheprobabilitythataunitofproductorservicewillpassthroughagivenprocesssteperror-free. ThroughputYield,Ytp=e–DPUProcess968Accept32Reject1,000Input(40Defects)ThroughputYield,Ytp=e-(40/1000)=0.961饒?zhí)魅鸷嚱棁[戌度諾存抓痛益氟禿拄薦凋稚缽吮樹步龜漬岸恤擂鍍仔桐6西格瑪介紹6西格瑪介紹79Throughputyield(Ytp)Throughp79FinalYield(Yf)800ShipProcessA1,000Input50ScrapProcessB950Input25ScrapProcessC925Input125Scrap FinalYield,Yf =QuantityShipped/QuantityBuilt =800/1,000=0.80Ashortcomingoffinalyieldisthatitfailstoconsiderthe“hiddenfactory”orrework.HiddenFactory:adhocsystemsandprocessessetuptocorrecterrorsmadeduringthemainstreamprocess.喬哮汪然蘆釘察匡抵那織烘橙南陶亂鉀槍淡評(píng)楓吊查掩煥呵襖凳單丫揩酋6西格瑪介紹6西格瑪介紹80FinalYield(Yf)800ShipProcess80RolledThroughputYield(Yrp) RolledThroughputYield =Ytp(A)Ytp(B)Ytp(C)

=0.7408×0.6393×0.5824 =0.2758675ShipProcessA1,000Input50ScrapRework200150ProcessB800Input(950)25ScrapRework300275ProcessC650Input(925)125ScrapRework250125

Defects =300

Ytp(A) =e–300/1,000=0.7408 Defects =425 Ytp(B) =e–425/950=0.6393 Defects =500 Ytp(C) =e–500/925=0.5824Defects=300售掏脯撻裝狗懊士酋該譏凝爐揣桓炸刀顧甭刊篩禮歹貍懇滔擁融存唉敗頑6西格瑪介紹6西格瑪介紹81RolledThroughputYield(Yrp) 81RolledThroughputYield(Yrp)Therolledthroughputyieldistheprobabilitythataunitofproductorserviceisabletopassthroughtheentireprocessd