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SIX SIGMA BY Dr.R.Raju Associate Professor Dept of Indl Engg Anna University

INTRODUCTION:

INTRODUCTION Quality is an important aspect of any manufacturing process. Only high quality products can survive in the market. Before 1980’s most of the industries produced the products and the defects were detected and segregated (inspection).

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Detection concept ensured the quality but increased the rework and rejections. In the present scenario, it is necessary to achieve the global quality which demands prevention concept . Six sigma is one of the most important prevention concepts. CONTD..

CONT’D:

CONT’D Six sigma is a powerful approach to achieve break through improvements in manufacturing ,engineering and business process. This approach relies on advanced statistical methods that compliment the process and product knowledge to reduce variation in processes. .

CONTD..:

CONTD.. It is a new way of doing business that would eliminate the existing defects efficiently and would prevent defects from occurring

MEANING OF QUALITY:

MEANING OF QUALITY “ Under six sigma quality is defined as” a state in which value entitlement is realized for the customer and provider in every aspect of the business relationships”.

What is Six Sigma:

What is Six Sigma Metric (Statistical Measure ) Used for representing Process Variation Higher the number before σ(3,4,5…) lesser the variation, higher the product quality and customer satisfaction.

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Method Benchmark Vision Philosophy Metric Tool Symbol Value 6

DEFINITION OF SIX SIGMA:

DEFINITION OF SIX SIGMA SIX SIGMA IS DEFINED AS” a disciplined ,data driven approach of continuously improving process quality and productivity to result in bottom line profitability.”

ORIGIN OF SIX SIGMA:

ORIGIN OF SIX SIGMA In 1980,motorola faced overseas competition seeking to dominate the electric industry by producing consistently higher quality products. Based on this significant threat to its leadership position, Motorola chairman Bob Galvin announced an initiative ,which is dedicated to improve the quality of internal process by a factor of 10 within 2 years.

ORIGIN OF SIX SIGMA CONTD..:

ORIGIN OF SIX SIGMA CONTD.. The internal focus of the program emphasized the idea to improve results for their customers. Six sigma was born. There after companies like General Electric and Allied Signals implemented six sigma successfully.

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BUSINESS PROBLEM BUSINESS SOLUTION STATISTICAL SOLUTION STATISTICAL PROBLEM DATA DRIVEN ANALYTICAL SIX SIGMA approach

SIX SIGMA CONCEPT:

SIX SIGMA CONCEPT If the process variation is controlled to 6 σ levels ,the defects expected is 3.4 parts per million opportunities ,even if there is a shift in the process mean by 1.5σ .

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Center / Location Spread / Dispersion Mean or Average  Variation / Standard deviation  Understanding Variation Process / product Characterization

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Understanding Variation 1 1 2 2 3 3 68.27% 95.45% 99.73%

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Target 6σ Total Process Variation = 6σ Normal or Symmetric Distribution Where σ : Standard Deviation Process Capability

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Natural or inherent variation experienced in a process. 6 σ Process Capability 3 σ 3 σ Valid only when the process is in a state of statistical control

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VARIATION ACTUAL PERFORMANCE VS SPECIFICATIONS Or Customer Requirements LSL USL Comparison

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LSL USL Tolerance(T) 6 σ 2700 ppm Total Process Variation = Tolerance or 6 σ = T Actual vs Specified Comparison

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Actual vs Specified Comparison LSL USL Tolerance(T) 6 σ Total Process Variation < Tolerance 6 σ < T or T=8σ 64 ppm 1 σ 1 σ

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USL Tolerance(T) 6 σ Total Process Variation < Tolerance 6 σ < T or T=10σ 0.6 ppm 2 σ 2 σ LSL Actual vs Specified Comparison

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LSL USL Tolerance(T) 6 σ Total Process Variation < Tolerance 6 σ < T or T=12σ 0.002 ppm or 2 ppb 3 σ 3 σ Actual vs Specified Comparison

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LSL USL Tolerance(T) 6 σ Total Process Variation < Tolerance 6 σ < T or T=12σ (with 1.5σ shift) 3.4 ppm 1.5 σ 4.5 σ 1.5σ Actual vs Specified Comparison

CRITICAL SUCCESS FACTORS FOR SIXSIGMA :

CRITICAL SUCCESS FACTORS FOR SIXSIGMA Customer centricity Voice of the customer. Requirements. Critical to quality (CTQ) Defects. Design for six sigma. Financial results. Management engagement Resource commitment. Execution infrastructure. Team work

KEY MESSAGES OF SIXSIGMA :

KEY MESSAGES OF SIXSIGMA Everything starts with the customer. The infrastructure for cultural change is the most powerful contribution of six sigma. Decision about which projects to pursue must be based at least in part on the potential impact on NPV. Sustained improvement is possible only with management engagement. CEO goals are translated to frontline projects and coordinated through an organization of people and technical resources. A standard problem-solving process and associated tool set provides the means for basing decisions on data.

THANK YOU :

THANK YOU