6σ標(biāo)準(zhǔn)差教材合集課件

6

OverviewSixSigma:-ADefinition-AppliedtoGE-GEQualityInitiative-WhyThisApproach?-OriginofSixSigma-The“BreakthroughStrategy”-ArrivingatSigmaSixSigmaStructureKeyConcepts&ToolsAPracticalExampleAnOverviewNotalotofDetails!!恐亮糠悟盲虹準(zhǔn)披罵鱉亂濱滇灌謀工溺驢賤眺瘓悔擊榴痹鞏寨鳥(niǎo)旁糕癌澆6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6OverviewSixSigma:AnOver6Overview

“SixSigma”Ifwecan’texpresswhatweknowintheformofnumbers,wereallydon’tknowmuchaboutit.Ifwedon’tknowmuchaboutit,wecan’tcontrolit.Ifwecan’tcontrolit,weareatthemercyofchance.MikelJ.HarryPresident&CEOSixSigmaAcademy,Inc.ARigorousMethodforMeasuring&ControllingOurQuality“...willbringGEtoawholenewlevelofqualityinafractionofthe

timeitwouldhavetakentoclimbthelearningcurveonourown.”JohnF.Welch,Jr.1995GEAnnualReport隙茍汛上傳虐股紗鼓牲肢沉官翔汀猿鑄靴說(shuō)絆渝邦嚷泉浴蘿聊潔吊錐吏濰6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview “SixSigma”6Overview

WhatDoes“Sigma”Mean?SigmaisaMeasureoftheConsistencyofaProcessIt(isAlsothe18thLetterintheGreekAlphabet!防飯親濘絹駁澈腆鄒焰嘔嗚莎躁歸愧遵杉讀牧率痕棘邱帆逛薄器勤墑淑腺6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview WhatDoes“WhyDoesGENeedAQualityInitiative?GERaisingTheBarNewGoaltobe“BestintheWorld”vs.#1or#2CustomersareExpectingMore,weMustDeliver“Ship-and-fix”ApproachnoLongerToleratedintheMarketAimtoSpeedPastTraditionalCompetitorsin5YearsGoalConsistentwithReducedTotalCostsWeMustAcknowledgeOurVulnerabilitiesPoorQualityThatImpactsCustomersProblemswithNPITooHighInternalCosts6Overview

WeNeedaMajorInitiativetoMoveFromWhereweAretoWhereweWanttobe捆共繕剔沸邯愛(ài)謊僻黔泥作姐淘苔雖樞犯憂哥控龐吞隕將幼掇叉郴樣癱窄6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材WhyDoesGENeedAQualityIni6Overview

WhyDoesGENeedAQualityInitiative?40%35%30%25%20%10%15%5%CostofFailure(%ofSales)DefectsperMillion3.4233621066,807308,537500,000Sigma654321EstimatedCostofFailureinUSIndustryis15%ofSales;TakingGEFroma3toa6CompanyWillSave~$10.5BillionperYear!性晾眨莎茵網(wǎng)妒貴匣崗東啤撬頓坪貝逝筒白媒緬嘆援禽顫瞪摯肘濁拖窯琴6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview WhyDoesGEWhy“SixSigma”?ProvenSuccessfulin“Quality-Demanding”Industriese.g.,Motorola,TexasInstruments(manyprocessstepsinseries)ProvenMethodtoReduceCostsHighlyQuantitativeMethod–ScienceandLogicInsteadofGutFeelIncludesManufacturing&Service(closetocustomer)andProvidesBridgetoDesignforQualityConceptsHasSupportandCommitmentofTopManagementItWorks!!!杏鴻胎訓(xùn)削鄧扛此矣咆蒂沽瀝墳瑤潦但拿語(yǔ)鍘戴喪費(fèi)葷交煽謾麓擊潔夜儈6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材Why“SixSigma”?ProvenSuccess6Overview

Sigma3456SpellingMoneyTime1.5MisspelledWordsperPageinaBook1MisspelledWordper30PagesinaBook1MisspelledWordinasetofEncyclopedias1MisspelledWordinalloftheBooksinaSmallLibrary$2.7MillionIndebtednessper$1BillioninAssets$570Indebtednessper$1BillioninAssets$63,000Indebtednessper$1BillioninAssets$2Indebtednessper$1BillioninAssets31/2MonthsperCentury21/2DaysperCentury30MinutesperCentury6SecondsperCentury6isSeveralOrdersofMagnitudeBetterThan3!!!Sigma:AMeasureofQuality籮薊玩牽扔麓殖餓退涸粳脂山產(chǎn)霉厄硼切發(fā)百騰鐵藕躬穩(wěn)掌鉆亮統(tǒng)繕售帕6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview Sigma3456Overview

WhereDoes“SixSigma”ComeFrom?MikelJ.HarryoneoftheOriginalArchitectsPreviouslyHeadedQualityFunctionatABBandMotorola

NowPresident/CEOofSixSigmaAcademyinPhoenix,ArizonaHasConsultedforTexasInstruments,AlliedSignal(andothers)CurrentlyRetainedbyGEtoTeachtheImplementation,DeploymentandApplicationofSixSigmaConcepts&ToolsLearningfromThoseWhoHavehadSuccessWith6WillAccelerateitsImplementationatGE摳詩(shī)容啼吝焰俐悄顫法肩毅婪犧恐炸趁氣拳矛說(shuō)擲走真群踞了避望膛渝津6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview WhereDoes6Overview

So...WhatisSixSigma?AMeasurementSystemAProblem-SolvingApproachADisciplinedChangeProcess“THESIXSIGMABREAKTHROUGHSTRATEGY”MeasureAnalyzeImproveControl丸勝吝硒忙咯嫌題?？飞萁輦z果螢鵲蟬踐檬放纏殉埂綢蕉飾耽宋矛們6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview So...Whati6Overview

How

DoWeArriveatSigma?Measuring&EliminatingDefectsisthe“Core”ofSixSigmaMeasurementSystemIdentifytheCTQsLookforDefectsinProductsorServices

“CriticaltoQuality”CharacteristicsortheCustomerRequirementsforaProductorServiceCountDefectsorfailurestomeetCTQ

requirementsinallprocessstepsDefineDefectOpportunitiesAnystepintheprocesswhereaDefectcouldoccurinaCTQ

ArriveatDPMOUsetheSIGMATABLEConvertDPMOtoSigmaDefectsPerMillionOpportunities23456308,53766,8076,2102333.4PPMDefectsperMillionofOpportunitySigmaLevel腥糕招善趟辱哺喬除廊芭賒蓮償割旅貞禽坍哄踞刁撒餾粱課抬郎險(xiǎn)喉蕾孵6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview HowDoWeA6Overview

MeasurementSystem23456308,53766,8076,2102333.4PPMSIGMALEVELDEFECTSperMILLIONOPPORTUNITYIRSTaxAdviceBestCompaniesAirlineSafetyAverageCompanyGEAirlineBaggageDoctor’sPrescriptionRestaurantBills

AverageCompanyin3to4RangeSomeSigma“Benchmarks”追泄束塌銻簿圭幣舜灑嚨審慨爺鈾奸梅用潮感巧違癌筏沛黨綴攏區(qū)右慘埠6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview Measurement6Overview

MeasurementSystemAGraphic/QuantitativePerspectiveonVariationAverageValueManyDataSetsHaveaNormalorBellShapeNumberofPeopleArrivingatCRDTime7:007:157:307:458:008:158:308:459:009:15炯選疫佬轉(zhuǎn)件綱壹諸僧棘洗像偽會(huì)璃鞠雖罕惡架敷滯玄藏聘曾侄嫩埂愿附6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview Measurement6Overview

ProblemSolvingApproachCenterProcessReduceSpreadXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXOff-TargetUnpredictableOn-Target

6HelpsusIdentifyandReduceVARIATIONdueto:-InsufficientProcessCapability-UnstableParts&Materials-InadequateDesignMargin矢攝援彪書(shū)嗅掙菇遍粹擋渡盤篙瞻支吏鎬勛櫥畦黔椿稼訣脂笛段吵端漳蟻6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview ProblemSolTargetUSLLSLTargetUSLLSLTargetUSLLSLCenterProcessReduceSpreadOff-TargetUnpredictableOn-TargetDefects6Overview

ProblemSolvingApproach“LowerSpecificationLimit”“UpperSpecificationLimit”LessVariationMeansFewerDefects&HigherProcessYields

戌氦艘饅瞬的牽脊頓孩奉怎體紹折裝元濟(jì)昂責(zé)隴聾儈應(yīng)遇豢達(dá)積涯見(jiàn)語(yǔ)拽6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材TargetUSLLSLTargetUSLLSLTarget6Overview

ProblemSolvingApproachKeyComponentsof“BREAKTHROUGHSTRATEGY”MeasureAnalyzeImproveControlIdentifyCTQ&CTP(CriticaltoProcess)VariablesDoProcessMappingDevelopandValidateMeasurementSystems

BenchmarkandBaselineProcessesCalculateYieldandSigmaTargetOpportunitiesandEstablish

ImprovementGoalsUseofParetoChart&FishboneDiagramsUseDesignofExperimentsIsolatethe“VitalFew”fromthe“TrivialMany”SourcesofVariationTestforImprovementinCenteringUseofBrainstorming

andActionWorkoutsSetupControlMechanismsMonitorProcessVariationMaintain“InControl”ProcessesUseofControlChartsand

ProceduresAMixofConceptsandToolsWillAlsoIntegratewithNPIProcess符灤鐵呼巳瓢葵鎳炎韋殲缽欣跑助折擦穩(wěn)寂進(jìn)是舍涵球遺悼躇斡悠四累真6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview ProblemSol6Overview

DisciplinedChangeProcessANewSetofQUALITYMEASURESCustomerSatisfactionCostofPoorQualitySupplierQualityInternalPerformanceDesignforManufacturabilityWillApplytoManufacturing&Non-ManufacturingProcessesandbeTracked&ReportedbyEachBusiness鳴觸藩人詭虧蹦相瓦險(xiǎn)衍奴嵌鑷他膜邁咐庇疏線徹騎難娶社涯責(zé)魁蔓輕魏6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview Disciplined6Overview

StructureQualityCouncilMembers:Labs&Functions“Pipeline”&BBProjectPrioritiesTraining&CertificationMeasurements&RewardsCommunicationsChampionsLeadership:OverallInitiativeProjectFundingHR:Training&RewardsBlackBeltsLead6ProjectTeams“Measure/Analyze”“Improve/Control”O(jiān)utwithBusinessesHereatCRDMasterBlackBeltsTeach6

MentorBlackBeltsMonitorBBProjectsWork“Pipeline”ProjectsAResourcePoolTeamMembersLearn/Use6ToolsWorkonBBProjectsPartofTheJobOutwithBusinesses6ProjectswiththeGEBusinesses筷凸藤驅(qū)識(shí)果朽洽涂蓋楷輾嫌粱笆由廁圓壽琴逐朱緞服囪閏鑒乒倚貌毒值6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview StructureQu卷盈紋粳唾劣憚埠繳斷小喘侈蔣雌賃隅旅去逛緞典芒村戀焰堤懶髓搏渤傲6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材卷盈紋粳唾劣憚埠繳斷小喘侈蔣雌賃隅旅去逛緞典芒村戀焰堤懶髓搏蛾勢(shì)抒式桿驕悠掃咆條柒娜姜蜀轉(zhuǎn)牲藐沏句插樸裴膽陸待峭陋賢悍敝膘吉6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材蛾勢(shì)抒式桿驕悠掃咆條柒娜姜蜀轉(zhuǎn)牲藐沏句插樸裴膽陸待峭陋賢悍敝

TabulationofGESixSigmaResults淵稻椅旱娩傣旱睛舀比坍嘎餾憨祟掩視莆施志晴卞墩貶念蜒抵年譯隱副胚6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材TabulationofGESixSigmaResBenefitTarget&UpdateCurrentbenefitslevel@10.865MMQPIDloading:

Carryoverfrom1999: 4.059CompletedProjects2000: 3.313ActiveProjects2000:

3.285Total: 10.865MM假湘昭昂宰丸梗煞曉遏脾索夜燥燴蔬撒動(dòng)終氖線甕旗李像紫涼錄澤俞缺狀6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材BenefitTarget&UpdateCurrent新些樣添毗艦額還擅汀瘧鈉皚蓮氏綏股娛好擄鴻脹舞皇株鍺步棲疑寵餒丹6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材新些樣添毗艦額還擅汀瘧鈉皚蓮氏綏股娛好擄鴻脹舞皇株鍺步棲疑寵KeyConcepts&Tools6Overview

劑盧短傻注席嘔畦汀監(jiān)借琺琢柵熾藩皂沾磕疆救晤如極菱怪京趙堵奠餒導(dǎo)6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材KeyConcepts&Tools6Overv6Overview

ChangingFocusFromOutputtoProcess

Y

Dependent

Output

Effect

Symptom

Monitor

X1...XN

Independent

Input-Process

Cause

Problem

ControlIdentifyingandFixingRootCausesWillHelpusObtaintheDesiredOutputf(X)Y=燕哄鉸玖拾擊懊枚差擾論挽優(yōu)保褂乳惶左米唯錦源息烹陰吳足訓(xùn)賬漾劑超6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview ChangingFoProcessCapability6Overview

SustainedCapabilityoftheProcess(longterm)USLTTime1Time2Time3Time4InherentCapabilityoftheProcess(shortterm)LSLTargetOverTime,a“Typical”ProcessWillShiftandDriftbyApproximately1.5乓稍局屯燦倉(cāng)萄膀迅讀哮斡申芝皖錫噓屎俊瀾逗商斯納籠觸風(fēng)節(jié)惟載輕投6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材ProcessCapability6Overview 6Overview

“ShortTermCentered”versus“LongTermShifted”SixSigmaCenteredLSLUSLTProcessCapabilitySHORTTERM.001ppm.001ppm+6

LONGTERMLSLUSLT3.4ppmSixSigmaShifted1.5

ProcessCapabilityHigherDefectYieldinLongTermProcessCapabilitythanShortTermProcessCapability-6

4.51.5唯硒焰滅瘍沸瘓頤揮孺啼膝力幕籌濤徘速?gòu)洑淠缚`祁絞乖譏病磨諱秒鉤巍6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview “ShortTerm6Overview

TyingitAllTogethershiftCDAB0.51.01.52.02.5123456CONTROLPOORGOODTECHNOLOGYPOORGOODABCDGoodControl/PoorTechnologyPoorControl/PoorTechnologyPoorControl/GoodTechnologyWORLDCLASS!!!shorttermProblemCouldbeControl,TechnologyorBoth滇罪雀魚(yú)囑雇猛綸挺庇倪酪虞介疇陸玫膚閹妖壽朝韋澎貴脖刀夢(mèng)凰作摘砂6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview TyingitAl6Overview

ShortTermCapabilityShortTermCapabilityRatio(Cp)Cp=

LSL-6USL

ExampleUSLLSL3.0==-3.06

3.0-(-3.0Cp=Cp=1LSLUSL2.50.53.0ProcessMean

TTargetA3Process

ThePotentialPerformanceofaProcess,ifitWereonTarget柳綴回位恭吟乒務(wù)逞懦圖逗外繞嗎艙著填埠霓搓炸菊寓爽憂巧漣香刨琢信6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview ShortTerm6Overview

LongTermCapability

(Cpk)CpCpk=LongTermCapabilityRatioExampleCp=1(previouschart)Target=-0.5

=0Cpk1-(-0.5-03=Cpk=0.83-Off-TargetPenaltyTarget-3

ThePotentialPerformanceofaProcess,CorrectedforanOff-TargetMeanLSLUSL2.50.53.0ProcessMean

TTargetA3Process熬周霹項(xiàng)綁躇鯨員嗚塘洲仔腦繃迢淑衷償羌駱譏褲轎秀廈啞商纜繳疊鈾椽6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview LongTermC6Overview

Z-ScaleofMeasureZ

=AUnitofMeasureEquivalenttotheNumberofStandardDeviationsthataValueisAwayfromtheTargetValue-3.0-0.53.0Z-Values

USLLSL2.50.53.0=ProcessMean

Z

TTarget0A3Process咐朱最俏待擯夯發(fā)土坡澈囪靛貪鍛羊占摹摹跳狹賄列償公涸隅兵顧屎肚捷6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview Z-ScaleoTheDefinitionsofYieldFinalTestProcess(Process4)PassProcess3Process1Process2100(UnitsTested)65708291Yield1Yield2Yield3Loss1Loss3RejectsLoss299125FirstTimeYield(Yft)=UnitsPassedUnitsTested=6570=0.93RolledThruputYield(Yrt)=(Yield1)(Yield2)(Yield3)....=91826570(((())))=0.65100917082NormalizedYield(Ynm)==1/n(Yrt)(0.65)1/4=0.89(n:TotalNumberofProcesses)6Overview

YieldExclusiveofReworkProbabilityofZeroDefectsAverageYieldofAllProcesses蛋蛀偽膩邵棋濁恥蛇預(yù)訃殖鶴桅繳蚊拜墓怒花紉院方針兢晌眉鯉烽順渴看6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材TheDefinitionsofYieldFinal6Overview

TheImpactofComplexityTheImpactofComplexityRolledRolledYieldYieldNumberofOperationsNumberofOperations1.001.000.900.900.800.800.700.700.600.600.500.500.400.400.300.300.200.200.100.100.000.001101001,00010,000100.0001,000,0001101001,00010,000100.0001,000,000ProcessMeanCenteredonEachOperationProcessMeanCenteredonEachOperation1101001,00010,000100.0001,000,0001101001,00010,000100.0001,000,000RolledRolledYieldYieldNumberofOperationsNumberofOperations1.001.000.900.900.800.800.700.700.600.600.500.500.400.400.300.300.200.200.100.100.000.00AstheNumberofOperationsIncreases,aHighRolledYieldRequiresaHighforEachOperation54366543ProcessMeanShifted1.5atEachOperation掖搪灶誠(chéng)筐棱庫(kù)包牲私匣渝膏茶哩稅點(diǎn)傈親佑寨侈義孿五迫唯樂(lè)鍵搗衛(wèi)簿6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview TheImpact6Overview

Baselining&BenchmarkinganExistingProcessp(x)DefectsBenchmarkBaselineEntitlementBenchmarkAWorld-ClassPerformanceEntitlementAchievablePerformanceGiventheInvestmentsAlreadyMadeBaselineTheCurrentLevelofPerformanceBaselining=CurrentProcess/Benchmarking=UltimateGoal豆凄互喀朝拒范蟻缸般墓捆獲哨凜腺酬泌峨搞鞠劫屜驚摧北鉸霄研咳胯仁6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview BaseliningSomeBasic6-RelatedTools6Overview

ScatterDiagramOverSleptCarWouldNotStartWeatherFamilyProblemsOtherParetoDiagramFrequencyofOccurenceReasonsforBeingLateforWorkArrivalTimeatWorkTimeAlarmWentOff捐徘凸記窘荊枕轎迷攆榮繪自梧儈鉀郁國(guó)蝴攫價(jià)校卒祝餓震紅諺渺臘冪罷6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材SomeBasic6-RelatedTools6MaterialsPeopleTheHistogramControlCharts6Overview

SomeBasic6-RelatedToolsTheFishboneDiagramMeasurementsMethodsTechnologyStatementCause&EffectBeingLateforWorkPlotofDailyArrivalTime9:157:007:157:307:458:008:158:308:459:00AverageValueNumberofPeopleArrivingatCRDTime族頂橋寡忿謬細(xì)頭孺奈彝澗碧濾懦距裙倍薩靈噬韶?fù)熳挡逼绲姨蚜ㄗ胫?σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材MaterialsPeopleTheHistogramCo6Overview

LCLUCLRangeChartROutofControlConditionLCLXUCLXBarChartSomeBasic6-RelatedToolsLCL=LowerControlLimitUCL=UpperControlLimitX=MeanR=AverageRangeMonitorsChangesinAverageorVariationOverTime混狙稈蛇繪腥墟統(tǒng)梅棵哨農(nóng)蒲幸湛音羅謊猛霸捧縷袒提屆舌摳踞夯肘太廳6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview LCLUCLRangeDesignofExperiments6Overview

SCREENINGOPTIMIZATIONCHARACTERIZATIONForExperimentsInvolvingaLarge

NumberofFactorsUsefulinIsolatingthe“VitalFew“fromthe“TrivialMany”ForExperimentsInvolvingaRelatively

SmallNumberofFactorsUsefulWhenStudyingRelativelyUncomplicated

Effects&InteractionsForExperimentsInvolvingOnly2or3FactorsUsefulWhenStudying

HighlyComplicatedEffects&RelationshipsDOEisMoreEffectiveThanTestingOneFactorataTime峪職煉獺桂墟董炕蝎樊瞬抿悔勾慕焉段拈加躬恥獵烏怒余迂宰燴倆繹孜螟6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材DesignofExperiments6Overvi6Overview

Usingthe“OneFactorataTime”Approach

ReduceCommutetoWorkto15Minutes(withoutworkinganabnormalworkschedule)

TheGoalTheVariables

TimeofDeparturefromHome&RouteTakentoWorkTheApproach

Try3PotentialRoutesatCurrentDepartureTime(7:45),SelecttheBest&VarytheDepartureTime‘tilwegetto15MinutesTimeofDeparture3217:157:307:458:008:15RouteCombinationSelectedTheResultUseRoute2andLeaveat7:15toReachGoal芭凄融只螢播往翅倡揀婪呢奉降是粗緞排別幕藤田母窒安誤杠拈引藐繪韌6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview Usingthe“6Overview

Using“DesignofExperiments”(DOE)TimeofDepartureDOE(i)BetterAccountsforInteractiveVariablesMissedby“OneFactorataTime”,and(ii)EfficientlySearchesfor“SweetSpot”inParameterSpaceTheVariablesTimeofDeparturefromHome&RouteTakentoWorkTheApproachVarytimeofDepartureandRouteSimultaneously,inaSystematicFashionTheResultABetterCombinationAllowing15MoreMinutesofSleep!!!ActualCommutingTimeAverages

(minutes)3217:157:307:458:008:15Route172023211915182019161215212018OriginalConclusionBestCombination“SweetSpot”

ReduceCommutetoWorkto15Minutes(withoutworkinganabnormalworkschedule)

TheGoal滋臃楞啥洽殿泥鏟語(yǔ)竿識(shí)狙拌摩炬包錐窯句辰乓徊冕鉤栽運(yùn)沫戌茨罐紛茵6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview Using“DesiAPracticalExample

(The“Cookbook”)6Overview

氨鴉肖前枉窄氈熬木奠顏琉蓮札蒙貸傷房飲礦宙藤羔軒訣刁璃八聽(tīng)毅促司6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材APracticalExample6Overvi6andBakingBreadYEASTFLOURUsinga12StepProcess6Overview

The“BETTERBREAD”Company宣猛般掠展雪蔭涉稽芍環(huán)拋齡球脆蚊才戲咐蟄淪瞻棍球?qū)⑾炞讋⒈淮亓?σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6andBakingBreadYEASTFStep1Selecting“CriticaltoQuality”(CTQsorY)WhatisImportanttotheCustomer?RiseTextureSmellFreshnessTasteY=Taste!!6Overview

Measure耐蓖財(cái)批餅瘁宦狙靛毗嘿窺敬芯殲篷憤淑迎軒翹疊桌花乓賭采磅敞打塹擅6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材Step1Selecting“CriticalStep2DefiningPerformanceStandardsforCTQsorY6Overview

HowCouldWeMeasureTaste(Y)?PanelofTastersRatingSystemof1to10Target:AverageRatingat8Desired:NoIndividualRatings(“defects”)Below7Y=12345678910TargetDefectsWorstBestButIsthistheRightSystem?Measure涼能速叁載離門鍘藻侮陌鄉(xiāng)疏薯謗矯需奇艷窺轅巒暗棱但陣買液媽柱偵坐6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材Step2DefiningPerformanc6Overview

Step3ValidatingtheMeasurementSystemforYHowCouldWeApproachThis?BlindfoldedPanelRatesSeveralLoafSamplesPut“Repeat”PiecesfromSameLoafinDifferentSamplesConsistentRatings*onPiecesfromSameLoaf=“Repeatability”ConsistentRatings*onSamplesAcrossthePanel=“Reproducibility”

“Repeatability”&“Reproducibility”SuggestValidMeasurementApproachPanelMember

Loaf1

Loaf2

Loaf3A5

8

9B 4

9

1C 4

9

2D 8

9

8E 4

8

2F 5

9

1G 8

9

2*WithinOneTasteUnitMeasure亥揍汛逗巾恿炭褪近瑣資贈(zèng)踴花聳矮吠耕光銀者霓孜騙幣軀川詛丹顏淵泅6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview Step36Overview

Step4EstablishProductCapabilityforY(Taste)Thisisa3Process!7Defects(ratingsbelow7)24Ratings(fromourpanel)=.292292,000Defectsper1,ooo,oooLoavesOR765432112345678910#ofRatingsRating64321143Defects<7Target=8AnalyzeHowDoWeApproachThis?BakeSeveralLoavesUnder“Normal”ConditionsHaveTasterPanelAgainDotheRatingAverageRatingis7.4

ButVariationistooGreatfora6Process3x10+4x9+6x8+4x7+3x6+2x5+1x4+1x31+1+2+3+4+6+4+3祥斗磋篙磋摯嶄幟坍帛薛磚萌寫醫(yī)膀弛業(yè)嬌骯見(jiàn)衣催音乘驗(yàn)筆插圍吳政戊6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview Step46Overview

Step5DefineImprovementObjectivesforY(Taste)HowdoweDefineImprovement?BenchmarktheCompetitionFocusonDefects(i.e.tasterating<7)DetermineWhatisan“AcceptableSigmaLevel”SetImprovementObjectivesAccordinglyMaybea5ProcessWillSuffice!1,000,000-100,000-.............................10,000-.............................1,000-.............................100-.............................10-.............................1-234567“BETTERBREAD”

BakingProcessBestCompetitorRangeforImprovementDefectsPerMillionSigmaScale

Freihofer

WONDER

PepperidgeFarm

SunbeamAnalyze惟嚎垮迸惦洋篙鉆氣等露演努梁瓶伎伐娶酪昧撈煞炔怒躇耽伊窖黑魏昏徐6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview Step56Overview

Step6IdentifySourcesofVariationinY(Taste)HowdoweDeterminethePotentialSourcesofVariation(Xs)?HavetheChefsBrainstormSomeLikelyOnesMightbe:-AmountofSaltUsed-BrandofFlour-BakingTime-BakingTemperature-BrandofYeast

YEASTFLOURMultipleSources:Chefs,Suppliers,ControlsAnalyze灤睡丙坤陵剝琴泵薔奮方嗎泰戊味草娠為妹抄農(nóng)譬攪轍喬庶潛勸別滿汾淮6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview Step66Overview

Step7ScreenPotentialCausesofVariation(Xs)HowdoweScreenforCausesofVariation(Xs)?DesignanExperimentUseDifferentSourcesofPotentialVariationHavePanelRatetheBreadUsedintheExperimentResultsLeadtothe“VitalFew”CausesYEASTFLOURSourceConclusionNegligibleMajorCauseNegligibleMajorCauseNegligibleFocusonThe“VitalFew”Improve堂劇養(yǎng)葉弗椽兔穆東噶譬蔡綱廁援征忻軍妝修攀斡慚玲姜烯巋受剪歐擁姬6σ標(biāo)準(zhǔn)差教材6σ標(biāo)準(zhǔn)差教材6Overview Step76Overview

Step8DiscoverVariableRelationshipsBetween“VitalFew”(Xs)andYHowdoweFindtheRelationshipBetweenthe“VitalFew”(Xs)andTaste(Y)?ConductaMoreDetailedExperiment

Focus:OvenTemperaturefrom325to375and3BrandsofFlourRUN#TEMPBRAND1325A2325