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Six-Sigma Management and Tools
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Six-Sigma Management and Tools
TKI 212 - Pengendalian Kualitas
Six-Sigma Management and Tools
What is Six-Sigma? Organizing Six-Sigma DMAIC overview DMAIC phases The Taguchi method The Taguchi method Design for Six-Sigma Using Six-Sigma from a contingency perspective
Six-Sigma Management and ToolsWhat is Six-Sigma?
Sigma ( ) is a greek letter used to designate a standard deviation (SD) in statistics
Six refers to the number of SDs from the specialized limit to the mean
Six-Sigma: about 0.5% of products will not meet specificationspecification
Six-Sigma Management and ToolsWhat is Six-Sigma?
Sigma Level Long-term ppm* defects
1 691,462
2 308,538
3 66,807 3 66,807
4 6,210
5 233
6 3.4
* ppm = Parts Per Million
Six-Sigma Management and ToolsWhat is Six-Sigma?
Six-Sigma is designed to handle the most difficult quality problems
% Quality Problems Techniques
90% Basic tools of Quality
Six-Sigma Management and ToolsOrganizing Six-Sigma
The key players
Champion. Work with black belts to identify possible projects
Master Black Belts. Work with and train new black belts
Black Belts. Committed full time to completing cost-reduction projects
Green Belts. Trained in basic quality tools
Six-Sigma Management and ToolsOrganizing Six-Sigma
In a company with 100 employees there might be:
One black belt Sixty green belts Some companies have yellow belts, employees
familiar with improvement processesfamiliar with improvement processes
Six-Sigma Management and ToolsDMAIC overview
Stands for:
Define Measure Analyze Improve Improve Control
Six-Sigma Management and ToolsDMAIC phases
Define Four Phases:
1. Develop the business case
2. Project evaluation
3. Pareto analysis 3. Pareto analysis
4. Project definition
Six-Sigma Management and ToolsDMAIC phases
Define Developing the Business Case:
1. Identify a group of possible projects
2. Writing the business case
3. Stratifying the business case into problem 3. Stratifying the business case into problem statement and objective statement
Six-Sigma Management and ToolsDMAIC phases
Define RUMBA is used to check the efficacy of the business case
1. Realistic
2. Understandable 2. Understandable
3. Measurable
4. Believable
5. Actionable
Six-Sigma Management and ToolsDMAIC phases
Measure Two major steps:
1. Select process outcomes
2. Verifying measurements
Six-Sigma Management and ToolsDMAIC phases
Measure Two major steps:
1. Select process outcomes
Tools Used:
Process may Process may XY matrix FMEA Gauge R&R Capability Assessment
Six-Sigma Management and ToolsDMAIC phases
Measure Two major steps:
1. Select process outcomes
2. Verifying measurements
Tools Used:Tools Used:
Use gauges, calipers and other tools Management System Analysis (MSA) is used to
determine if measurements are consistent
Six-Sigma Management and ToolsDMAIC phases
Measure Two major steps:
2. Verifying measurements
Gauge R&R
Most commonly used MSA Most commonly used MSA Determine the accuracy and precision of your
measurements
Six-Sigma Management and ToolsDMAIC phases
Analyze Three major steps:
1. Define your performance objectives (Xs)
2. Identify independent variables
3. Analyze sources of variability3. Analyze sources of variability
Six-Sigma Management and ToolsDMAIC phases
Analyze Three major steps:
1. Define your performance objectives (Xs)
Identify the independent variables where data will be gathered will be gathered
Process maps, XY matrices brainstorming and FMEAs are the tools used
Six-Sigma Management and ToolsDMAIC phases
Analyze Three major steps:
3. Analyze sources of variability
Use visual and statistical tools to better understand the relationships between dependent and the relationships between dependent and independent variables
Six-Sigma Management and ToolsDMAIC phases
Improve Off-line experimentation
ANOVA Taguchi
Six-Sigma Management and ToolsDMAIC phases
Control Manage the improved processes using control charts
Six-Sigma Management and ToolsThe Taguchi method
Design of Experiment (DOE) Robust design - designed so that they are inherently
defect free Concept Design Parameter Design Tolerance Design Tolerance Design
Six-Sigma Management and ToolsThe Taguchi method
The Taguchi Method provides:1. A basis for determining the functional relationship
between controllable factors
2. A procedure for examining the relationship between random noise and product or service variability
Six-Sigma Management and ToolsThe Taguchi method
Design of Experiment (DOE) Robust design - designed so that they are inherently
defect free Concept Design - examining competing technologies
Six-Sigma Management and ToolsThe Taguchi method
The Taguchi Process 1. Problem identification
2. Brainstorming session
3. Experimental design
4. Experimentation
Analysis 5. Analysis
6. Confirming experiment
Six-Sigma Management and ToolsDesign for Six-Sigma
Used in designing new products with high performance Instead of DMAIC
1. DMADV
2. IDOV
Six-Sigma Management and ToolsDesign for Six-Sigma
Used in designing new products with high performance DMADV
1. Design
2. Measure
Analyze 3. Analyze
4. Design
5. Verify
Six-Sigma Management and ToolsDesign for Six-Sigma
Used in designing new products with high performance IDOV
1. Identify
2. Design
3. Optimize3. Optimize
4. Verity
Six-Sigma Management and ToolsFailure Six-Sigma from a Contingency Perspective
Reasons for Six-Sigma failure: 1. Lack of leadership by champions
2. Misunderstood roles and responsibility
3. Lack of appropriate culture for improvement
Six-Sigma Management and ToolsFailure Six-Sigma from a Contingency Perspective
Reasons for Six-Sigma failure: 1. Lack of leadership by champions
2. Misunderstood roles and responsibility
3. Lack of appropriate culture for improvement
4. Resistance to change and the Six-Sigma structure 4. Resistance to change and the Six-Sigma structure
5. Faulty strategies for deployment
6. Lack of data
Six-Sigma Management and ToolsSummary
The process for Six-Sigma is define, measure, analyze, improve and control
Keys to Six-Sigma success are skilled management, leadership and long-term commitment
Six-Sigma Management and Tools
TKI 212 - Pengendalian Kualitas
Six-Sigma Management and Tools
What is Six-Sigma? Organizing Six-Sigma DMAIC overview DMAIC phases The Taguchi method Design for Six-SigmaUsing Six-Sigma from a contingency perspective
Six-Sigma Management and ToolsWhat is Six-Sigma?
Sigma ( ) is a greek letter used to designate a standard deviation (SD) in statistics Six refers to the number of SDs from the specialized limit to the meanSix-Sigma: about 0.5% of products will not meet specification
Six-Sigma Management and ToolsWhat is Six-Sigma?
Sigma Level
Long-term ppm* defects
1
691,462
2
308,538
3
66,807
4
6,210
5
233
6
3.4
* ppm = Parts Per Million
Six-Sigma Management and ToolsWhat is Six-Sigma?
Six-Sigma is designed to handle the most difficult quality problems
% Quality Problems
Techniques
90%
Basic tools of Quality