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6Sigma6Sigma23MeasureDefineAnalyzeImproveControlSixSigma-SixSigma-SixSigma-SixSigma-SixSigmaProjectProject-Project-Project--Team-ProcessMap-ProjectCOPQIntroductionDefine46Sigma6SigmaQualityInspectionQualityControlTQM6Marching619001930195019901988Motorola19881988Motorola5历历年量理念(MalcolmBaldrigeNationalQualityAward)異行行異來益異益6Johnson&JohnsonKodak71σ1σSixSigma6σ(Target)(Target)p()8SixSigmaSixSigma?σ(Z)σ(Z)9———·1011SixSigma?Process-Process-3.4DPMO(DefectsperMillionOpportunities)-“6σ”-“”-“(Process)”--Process/SixSigma12SixSigmaSixSigmaσσPPMPPM2308,537366,80746,210523363.499.99966%(6σ)99.99966%(6σ)99%(3.8σ)99%(3.8σ)•20,000•5,000•200,000•7•1.7•6813$CycleTime/?SixSigma14SixSigmaTreeSixSigma36;19,60023:534:1045:2756:703σ3σ4σ-Process4σ-Process7Process5σ-5σ-SixSigma6σ6σ15SixSigmaσ?(Sigma),σProcessσ((USL)USL)-3-2-1+1+2+3??((LSL)LSL)1()?16Process()6su()0.001ppmLSLsUSLUSLLSL12σ(σ12)0.002ppm12s6s0.001ppmSixSigma3.4ppm?17Processu()3.4ppmLSLUSLProcess1.5sUSLLSL4.5s3.4ppm4.5s1.5s7.5s0ppm(Target)SixSigma3.4ppm?18SixSigmaProcess19SixSigma:CTQ(CriticalToQuality:)Project()()()()-----Snack-----Snack--(Refill)----(Refill)--1)ConferenceserviceSixSigma20XXY()()X1...XN-ProcessXY?f(X)f(X)Y=Y=ProcessSixSigma21(HiddenFactory)-ProcessCOPQ(CostOfPoorQuality:)--SixSigmaProcessNOTOKOK,,90%90%VA(ValueAdded)NVA(Non-ValueAdded)VAProcessNVASixSigma22-DATA,DATA---DMAIC-DMADV(DFSS)SixSigma23X?fX?X(SPC)SixSigmaY=f(X1,X2,…,XN)24BlackBeltGreenBeltGreenBeltGreenBeltGreenBeltChampion•Project•ProjectTracking•ProjectChampionChampionMBBMBBBlackBeltBlackBeltMBB•BlackBeltCoach•6/•ProjectCoachBB•ProjectLeader•GreenBeltCoach•ChangeAgentsGB•BBProject•GB•ChangeAgentsSixSigma25SIXSIGMA1)年度行2BB,GB參634度Champion1626立勵行62立36勵行6行261)參6料行參GB綠GreenBelt1)領62領行3理4度BBBlackBelt1)100%行練2領力3六4Champion來行5MBBMasterBlackBelt27σCOPQ610%510-15%415-20%----------------------------------------320-30%230-40%3σCOPQ()20%SixSigma28SixSigma••••6·•••Vision•••••••·•·•6•·•GBM•••VisionProcessCOPQ6Sigma.ProgramProjectProcess6SigmaModel.System6SigmaDataσσσσ29•VOCCTQ•Biz’Big-Y•••COPQ••DMAIC•DFSS/TSSSixSigmaProcessVOCCTQBiz’Big-YProcessProject/COPQ:Sigma:ProcessDMAIC:DFSS:σ30SixSigmaCOPQ,CTQProcessBigYProjectProcess/MBB/BB—DMAIC/DFSS—//—Process——Project——AuditSixSigmaSixSigmaLeader——/—31DMAICDMADVProjectProcessDMAICDMAICDMADVDMAICDMADVR&DCTQDesignSixSigma32-Process--ProcessDMAICDefine-Measure-Analyze-Improve-Control-Process,--ProcessProcessDMADVDefine-Measure-Analyze-Design-VerifyDMAICDMADVSixSigma33XsVitalFewXsVitalFewXs()VOC/VOB/COPQProject⌦⌦DOE⌦⌦ProjectVitalFewXs/⌦Project⌦ProjectσXs⌦⌦SOP⌦Define()Measure()Analyze()Improve()⌦XsControl()⌦DATA⌦DATADMAICRoadmap34MeasureDefine(Baseline)XsXsProjectProjectMSA(GageR&R)C-EDiagramFDM,FMEABGMCOPQParetoSIPOCMSA(GageR&R)(sigma)ProcessMapC-EDiagramFMEAXsProjectProcessMapProjectVOC/VOB/COPQCTQCTQProjectDMAICRoadmapDefineMeasureAnalyzeImproveControl35ControlImproveAnalyzeVitalFewXs()VitalFewXsControlPlanMSA(GageR&R)DOEPilotBenchmarking(BestPractice)&CHARTLeanSOPMSA(GageR&R)FinalReport,SYSTEM-DOE-DataVitalFewXsDOE-/--DataVitalFewXsDMAICRoadmapDefineMeasureAnalyzeImproveControl36MeasureDefineAnalyzeImproveControlSixSigma-SixSigma-SixSigma-SixSigma-SixSigmaProjectProject-Project-Project--Team-ProcessMap-ProjectCOPQIntroductionDefine37废LeadTime(5~8%)()(15~20%)COPQ(CostofPoorQuality:)COPQ,–()=COPQ38COPQQ-Cost()COPQ()/(Appraisal/InspectionCosts)(InternalFailureCosts)(ExternalFailureCosts)COPQQ-COST(PreventionCosts)39COPQ••Loss••Loss&3ParadigmShift•Process•Loss•Process•Loss456&403sigma4sigma5sigma6sigma66,8076,2102333.4DPMO20∼30%15∼22%5∼8%15∼20%11∼15%4∼5%10∼15%7∼11%3∼4%10%7%3%In-visualVisualCOPQ()σ4-’057/.VisualCOPQ:17500.In-VisualCOPQ:52500σCOPQCOPQ41COPQ–/HiddenFactoryCOPQ42(PreventionCosts),COPQ-(QualityPlanning)--(ProcessPlanning)-(ProcessControl)-(QualityAudits)--COPQ434445(ExternalFailureCosts)-ShipBack-------COPQ46COPQ()NOCOPQ1*2*3*4*Utility5/*6/*7M*T*+M*T*+M*T*8**+9++Utility+10++—++11—*=COPQ47COPQ1.2.3.DATA()4.COPQProject:Project:VitalfewXsProject:Project:COPQCOPQ48DefineBGM,COPQ,DrillDownTree,Brainstorming,(Pareto)ProcessMap(SIPOC)ProjectCTQsProjectProjectProjectProject/ProjectTeam员TeamProjectProject-VOBCTQBGMDrillDown-COPQCTQ-VOCCTQVOCVOCCTQProject/MeasureAnalyzeImproveControl49MeasureDefineAnalyzeImproveControlSixSigma-SixSigma-SixSigma-SixSigma-SixSigmaProjectProject-Project-Project--Team-ProcessMap-ProjectCOPQIntroductionDefine50Project1.2./3.4./51ProjectVOC/VOBCTQ,COPQCTQ/COPQProjectProjectVOBCTQCOPQCTQVOCCTQProjectProjectProject52Project(Sources),CostofPoorQuality:,(Audits)COPQProjectProjectProject53CTQCTQCTQ(Top-down)COPQProcessCOPQProcessCTQ()CTQCTQVOC:VoiceofCustomerCCR:CriticalCustomerRequirementVOB:VoiceofBusinessCBR:CriticalBusinessRequirement(Quality,Cost,Delivery)VOC-CCRVOC-CCRBenchmarkingCBR-VOBCBR-VOBProjectCTQCTQCTQCTQCTQCTQCTQCTQProject54Project•VOC(VoiceofCustomer):•CTQ(CriticaltoQualityCharacteristic):ProcessCTQVOCCTQProjectProject55?---ProcessProjectProjectCTQ,Group56DataSources-Data-(Interview)-ProductProcess/FocusGroup-Group(Su