Six Sigma General View

SixSigmaLearningObjectives•TheNeedforSixSigma•SixSigma-Vision,PhilosophyandStatisticalMethod•BreakthroughStrategyandFocusofSixSigma•SixSigmaSystem-BlackBelts,GreenBeltsandManagementWhyImplementSixSigmaNow?•“NothingNew”–MostoftheSixSigmatoolshavebeenaroundfordecades–NeglectedduetodifficultyanddisciplineBUT•Worldwidecompetition–Makesneglectdangerous•Computingresources–Makesapplicationpossible99%GoodisNotGoodEnough•5,000incorrectsurgicalprocedureseachweek•20,000lostarticlesofmaileachhour•Noelectricityforalmost7hourseachmonth•Unsafedrinkingwaterforalmost15minuteseachdayWhereDoesIndustryStand?7SigmaScaleofMeasure1,000,000100,00010,0001,000100101PPM••RestaurantBillsDoctorPrescriptionWritingPayrollProcessingOrderWrite-upJournalVouchersWireTransfersAirlineBaggageHandlingPurchasedMaterialLotRejectRateDomesticAirlineFlightFatalityRate(0.43PPM)Best-in-ClassAverageCompany345621IRS-TaxAdvice(phone-in)(140,000PPM)SixSigmaViewofQuality•100%InspectionInefficient•ManagementinvolvementisKEY•FocusontheProcess•ContinuousImprovementisaPhilosophyofDoingBusiness•ReductionofVariationSixSigmaFocusDelightingtheCustomerthroughFlawlessExecutionRapidBreakthroughImprovementAdvancedBreakthroughToolsthatWorkPositiveandDeepCultureChangeRealFinancialResultsPassion+Execution=FastandLastingResultsSixSigmaisaVisionTheVisionofSixSigmaistodelightcustomersbydeliveringworld-classqualityproductsthroughtheachievementofSixSigmalevelsofperformanceineverythingwedo.SixSigmaisaPhilosophyThePhilosophyofSixSigmaistoapplyastructured,systematicapproachtoachievebreakthroughimprovementacrossallareasofourbusiness.SixSigmaisaStatisticalMethod•Knowwhat’simportanttotheCustomer(CTQ’s)•Reducedefects•Centeraroundtarget•ReduceVariationBreakthroughStrategySixSigma–SixSigmaEnablesBreakthroughLevelImprovement!SixSigmaBreakthroughStrategy•Trained&Dedicatedindividuals•AnalyticalExpertise•70%Improvementperproject1234TimeinYearsStandardApproaches•CurrentTools•Kaizen•LeanManufacturing•Re-engineering•TypicalTQMTheproblemwithcontinuousimprovementsastheonlygoalOrganizationseesimprovementBUTlosesthegame.Sigmaisastatisticalunitofmeasurethatreflectsprocesscapability.Thesigmascaleofmeasureisperfectlycorrelatedtosuchcharacteristicsasdefects-per-unit,parts-per-milliondefective,andtheprobabilityofafailure/error.2308,537366,80746,210523363.4PPMProcessCapabilityDefectsperMillionOpp.SixSigma-AggressiveGoalWhatdoesa6sigmaprocesslooklike?mAverageDeviationfromMean1TUSLp(d)1234563Thisisa6SigmaProcess99.99966%Good(6Sigma)20,000lostarticlesofmailperhourUnsafedrinkingwaterforalmost15minuteseachday5,000incorrectsurgicaloperationsperweekTwoshortorlonglandingsatmostmajorairportseachday200,000wrongdrugprescriptionseachyearNoelectricityforalmostsevenhourseachmonthSevenarticleslostperhourOneunsafeminuteeverysevenmonths1.7incorrectoperationsperweekOneshortorlonglandingeveryfiveyears68wrongprescriptionsperyearOnehourwithoutelectricityevery34years99%Good(3.8Sigma)SixSigma-PracticalMeaningIfwearesogoodatX,whydoweconstantlytestandinspectY?X1...XNIndependentInput-ProcessCauseProblemControlTogetresults,shouldwefocusourbehaviorontheYorX?f(X)Y=FocusonXratherthanY,asdonehistoricallyYDependentOutputEffectSymptomMonitorFocusofSixSigmaKPIVKPOV*StrategyofSixSigma•Identifyingcriticalaspectsofthebusinesswithproblemsoropportunitiesforimprovement•TargetingthosecriticalareasanddesignatingimprovementeffortsasSixSigmaBlackBeltprojects•SelectingBlackBeltsfromamongthebestpeopletoworkontheprojects--fulltime•Ensuringthesepeoplehavethetime,tools,andresourcestheyneedtosucceedIncludes4monthsofextensiveSixSigmatraining(4weeksclassroom,12weeksexecution)BlackBeltsleadimprovementeffortsonprojectschosenbytheirChampionsDedicatedresourceofhighlyskilled,trainedandfocusedindividualsRigorousselectioncriteria...amongthebestpeopleontheirsiteABlackBeltperforms4to6projectsperyearwithaminimumof2yearsassignmentcommitmentResultsinupto$1Msavings/year/BlackBeltTheBBensuresthatthespecificprocess(sequence)isfollowedforeachproject---Measure,Analyze,Improve,andControlFocusisonfixingthecausesusingthesetools-Y=F(X)UtilizesproblemsolvingtoolsprovidedthroughTrainingandMiniTabstatisticalsoftware(DOE,FMEA,etc.)SomeBlackBeltsareselectedtoperformGreenBelttrainingSixSigmaSystem-BlackBeltsGreenBeltsaretheprofessional,salariedemployees,includingmanagers,whoarenotChampionsorBlackBelts.TheyhavekeyrolesindeployingSixSigma.AssistBlackBeltsincompletingsectionsoftheirprojectsReceivedetailedtrainingoverthenextthreeyearstoimprovetheirdatacollection,analysisandproblemsolvingcapabilityWillapplytheirlearningintheirdailyperformanceoftheirjobsWillbroadlyusemanyoftheSixSigmamethodsandtools,includingFMEA,DOE,SPC,etcWillbeready-trainedasthefirstroundofBlackBeltscompletetheirtwo-yearassignmentsSixSigmaSystem-GreenBeltsManagementisresponsibletohelpdrivethetotalemployeepopulationtoahigherlevelofproblemsolvingproficiencyIdentifiestheirbestcandidatesforBlackBeltappointmentDemonstrateshighenthusiasmtokeepSixSigmamovingforwardProvidestheleadatgettingG