Six Sigma general

MemberoftheBekaertGroupWhatisit?Howtoimplementit?ConditionsforsuccessFRANCEDC/vv/17812BekaertConsultingFranceContentsWhatisSixSigma?AsmeasureforprocesscapabilityAmethodologyHowtoimplementSixSigma?ConditionsforsuccessDC/vv/17813BekaertConsultingFrance1WhatisSixSigma?DC/vv/17814BekaertConsultingFrancePROCESSinputresultExellentresultsrequireexcellentprocessesDeliver(nearly)alwaysthedesiredresultsReducevariabilityAmbition:6SigmaProcessCapability(3.4defectspm)SixSigmaasmeasureforprocesscapabilityDC/vv/17815BekaertConsultingFranceDefectsandtheHiddenFactoryManufacturingVariationCausesAHiddenFactoryIncreasedCost-LostCapacityYieldAfterInspectionorTestEachdefectmustbedetected,repairedandplacedbackintheprocess.Eachdefectcoststimeandmoney.ScrapReworkHiddenFactoryNOTOKOperationInputsInspectFirstTimeYieldOKTime,cost,people90%CustomerQualityDC/vv/17816BekaertConsultingFranceToincreaseaprocessperformance,youhavetodecreasevariation.ImportanceofReducingVariationLessvariationprovidesGreaterpredictabilityintheprocessLesswasteandrework,whichlowerscostsProductsandservicesthatperformbetterandlastlongerHappiercustomersDC/vv/17817BekaertConsultingFranceLSLUSLDefectsProcessCapabilityInadequateDesignMarginInadequateProcessCapabilitySupplierVariationInadequateMeasurementCapabilityaveragess“Variation”and“ProcessCapability”DC/vv/17818BekaertConsultingFrance23456308,53766,8076,2102333.4sPPMProcessCapabilityDefectsperMillionOppty.6Sigma???%Non-Defective69.1%93.32%99.379%99.9767%99.99966%DC/vv/17819BekaertConsultingFrance6s6sCp=2Cpk=1,51,5s6sns=66sandCp,CpkDC/vv/178110BekaertConsultingFranceWhyppm?*1,5sshiftApproachClassicalNew,410,3320,663141,334,51,5NumberofsigmainhalfthetoleranceintervalCp561,662Cpk*_0,160,50,8311,161,5Ppm*__66.8106.2071.3502333,4Costofquality(%)__25%15%10%7,5%5%DC/vv/178111BekaertConsultingFranceIfweaccept99.9%good,then...1hnondrinkablewatereachmonth500«failed»surgerieseachweekinFranceInFrance:2babiesfallingoffthe«labour»tableeachday1000lostlettersperhour15000chequeonthewrongaccounteachdayDC/vv/178112BekaertConsultingFranceCompaniesinvolvedinSixSigmatoday:Someresultsthatwerepublishedinthepress:Dupont:benefitsexceed$150million/year(DowJonesBusinessNews-February2,2000).Dow:Savingsofabout$250.000perproject.Annualsavings$1billion(Chemicalweekmagazine-March1,2000).Black&Decker:Expectsearningspersharegrowthofatleast15%forthenextthreeyears(ReutersNewsService-February15,2000).AlliedSignal:Costsavingsexceeding$800msince1995GeneralElectric:mostadmiredcompanythreeyearsrunning,andconsistentlyincreasinggrowthandprofit.Costsavingsexceeding$2BGeneralDomesticAppliances:Costsavingsof£7,5m1999/2000DC/vv/178113BekaertConsultingFranceCompaniesinvolvedinSixSigmatoday:GenericSixSigmaMetricsSeasonedBlackBeltscompletethreetofiveprojectsannually$150.000-$200.000averagesavingsperprojectAnnualsavingsdeliveredperBlackBelt$450.000-$1.000.000RuleofthumbfornumbersofBlackBelts:1-3%ofemployeesDC/vv/178114BekaertConsultingFranceSIXSIGMAasmethodology...AsystematicapproachforbreakthroughimprovementrealisationsusingasolidandsoundlybasedtoolsetdeployedthroughouttheorganizationDC/vv/178115BekaertConsultingFranceSIXSIGMAasmethodology...AsystematicapproachforbreakthroughimprovementrealisationsusingasolidandsoundlybasedtoolsetdeployedthroughouttheorganizationDC/vv/178116BekaertConsultingFranceASYSTEMATICAPPROACH...SelectionofprojectsManagingtheimprovementprojectsSustainingthegainsBusinessstrategy&resultsSignificantgainsThinkprocessProjectfiltersLeadershipbuy-inProjectManagementTraining(BB/GB/YB)TeamworkReviewofprogressReward&recognitionProjectlevelOrganizationallevelDC/vv/178117BekaertConsultingFranceSelectionofprojects:PRIORITIZEContributingtoyourBUSINESSRESULTS!!LookforSIGNIFICANTGAINSwithinREASONABLETIMINGUsethecorrectPROJECTFILTERS!!ValueforthecustomerDefectsperunitCostofpoorqualityCycletimeEnsureLEADERSHIPBUY-INDC/vv/178118BekaertConsultingFranceManagingforimprovement-Training...Enhancedimprovementrealisationskills*Leadership*MasterBlackBelt(MBB)*BlackBelt(BB)*GreenBelt(GB)*YellowBelt(YB)DC/vv/178119BekaertConsultingFranceDefinetheproblem6SIGMADMAICAnalyseImproveMeasure•Definesteps•Confirmgains,goals•Formalisecustomersupplierrelations•Getvoiceofthecustomerintheproject•Formalisethemodifiedprocess•ImplementSPC•Evaluateresults•Learningpoints•DevelopmeasurementsofCTQ•Selectcriticalimputs•Preparedatacollection•RealiseR&Rstudy•Measureprocesscapability•Processanalysis(value)•Dataanalysis•Rootcauseanalysis•Statisticaldatahandling(regression,DOE,multivary…)•Imaginesolutions•Evaluatesolutions•Chooseoptimalsolution•Analyserisks•PlanimplementationManagingforimprovement:Theroadmap(1)DC/vv/178120BekaertConsultingFrance1/Define6SIGMADMADV²3/Analyse4/Design2/Measure•Businesscase•Charterdevelopment•Multigenerationplan•Projectrisk•Controlplans•Mistakeproofing•Upscaling•Validation•Implementationplaning•SIPOC•Stakeholderanalysis•Voiceofthecustomer•QFD•Qrequirements•Conceptgeneration•Conceptselection•Mappingandsimulation•Proactiver