奥特利夫精益生产之--6SigmaIntro

PRIVATE/PROPRIETARY1APSTrainingModuleQF–6SigmaAutoliv14-April-2006QF-TM-004-C2.0PROPRIETARY2QualityassuranceQualitymethodsSixSigmaStandardsPullsystemSafety&ErgonomyDon’tjudge,don’tblame!Flexibility&MotivationDisciplinetostandardsContinuousimprovementProcess&ResultQualityfirstProfitabilityCompetitivenessSatisfactionEmployeeinvolvementTeamwork5SMudaeliminationTPMJustintimeLeveling&CapacityLineconceptsContinuousflowTakttimeFrequentdeliveriesSixSigmaPROPRIETARY3WhythistrainingDuringthistrainingyouwilllearn:•What6Sigmais•Ameasurementofquality•Aproblemsolvingmethod•Examplesoftoolsin6SigmaPROPRIETARY4Whatis6SigmaSigmaistheGreekletterusedtorepresentvariation•σAsigmalevelisameasurementofquality•A6Sigmalevelprocesscreatesclosetonofailures•Asigmalevelisameasurementofhowwelltheprocessmeetscustomerspecifications6Sigmaisaproblemsolvingmethod•Customercentered•Systematic•DatadrivenPROPRIETARY5AMeasurementofQualityPROPRIETARY62s308,5373s66,8074s6,2105s2336s3.4AMeasurementofQualityA6Sigmaprocesshasonlyabout3.4ppm!SigmaLevelPPMPROPRIETARY7AMeasurementofQualityOutof365RoundsperYear2s6missedputtsperround3σ~1missedputtperround4σ1missedputtevery9rounds5σ1missedputtin1.5years6σ1missedputtin45yearsPROPRIETARY8AProblemSolvingMethod6SigmaisasetofCustomer-Centered,Systematic,DataDriventoolsandmethodstohelpimproveprocessesandtherebysolveandpreventproblems.PROPRIETARY9APSToolboxTheAPSToolboxisexpandedwiththe6SigmaToolstosolvemorecomplexproblemswithincreasedefficiencyNumberofCasesProblemComplexity6Sigma5WhyPDCAAPSToolboxPROPRIETARY10CustomerCentered•Whoisthecustomer?•Whatiscriticaltothequality(CTQ)forthecustomer?•Howarethecustomer’sexpectationsnotbeingmet?ActionsbasedondataarethekeytoCustomerSatisfactionPROPRIETARY11DefineMeasureAnalyzeImproveControlDMAIC1-Formateam2-Describetheproblem6-Evaluateresults3-Implementcontainmentactions4-Identifyrootcause7-Preventrecurrence8-Congratulatetheteam5-Choose&implementcorrectiveactions8-DSystematic6Sigmafollowsaroadmap•Tolinktoolsmorepowerfullytogether•ToguidetheteamthroughtheproblemPlanDoCheckActPDCAPROPRIETARY12TheDMAICMethodDMAICDefineprojectorproblemMeasurecurrentsituation•Processbehaviorcharts•Capabilityanalysis•ParetochartsCreateCause&EffectMatrixSelectcorrectiveactionsDocumentResultsDevelopProjectPlan•Selectteam•Businesscase•SMARTobjective•Projectscope•Keymetric•OperationaldefinitionConductMeasurementSystemAnalysis(MSA)CreateVMEAImplementCorrectiveactionsImplementcontrolmethod•Controlplan•Standards•Trainingmatrix•SWI•Audit•SPCCreateProcessMaporFishboneDiagramRootcauseanalysisprocess•VMEAActions•Testingpotentialrootcauses•OFATTests•DOETestsVerifycorrectiveactions•Capabilityanalysis•Processbehaviorcharts•OFATTests•DOEConfirmatoryDocumentLessonsLearnedDeterminecustomer’sCTQsOptimizeProcess•DOETests•ResponseOptimizer•Responsesurfacemodels(RSM)Confirmrootcause•Reproducefailure•OFATTests•DOETestsPROPRIETARY13Systematic6Sigmaisaboutreducingvariation•Understandthesystem•Y=f(x)•Determinetodominatesourceofvariation•ControlthedominatesourcePROPRIETARY14InputscausingtheproblemathandAllpossibleinputvariablesProcessMapC&EMatrixTheDMAICMethodProcessMap•CollectsallknowninputandoutputvariablesCauseandEffectMatrix•PrioritizesthevariablesmostlikelytohaveamajorimpactVMEA•StudieshowselectedvariablescancausetheprocesstofailStatisticaltoolsarethenusedtoquantifytherelationshipbetweentheseselectedinputandoutputvariablesVMEAPROPRIETARY15DataDrivenKeyConcepts“Variablealwaystrumpscategorical”•Variabledataismorepowerfulthancategoricalbecauseitcontainsmoreinformation“Dataisinnocentuntilprovenguilty”•Variationinaprocessisconsideredtoberandomuntilevidenceshowsotherwise“Agraphisworthathousanddata”•ThecorrectgraphorstatisticaltoolcanobjectivelymakeconclusionsmuchbetterthanrawortabulateddataPROPRIETARY16DataDrivenAttemptingtocontrolvariationwithoutunderstandingandquantifyingit,simplyaddsonemoresourcetotheproblemPROPRIETARY17DataDrivenBasedonthedata,whatisthisprocessdoing?•Gettingbetter•Gettingworse•StayingthesameWhatwillthe%scrapbeinthreemonths?PROPRIETARY18DataDrivenBasedonthechart,whatisthisprocessdoing?•Gettingbetter•Gettingworse•StayingthesameWhatwillthe%scrapbeinthreemonths?PROPRIETARY19DataDrivenBasedonthechart,whatisthisprocessdoing?•Gettingbetter•Gettingworse•StayingthesameWhatwillthe%scrapbeinthreemonths?PROPRIETARY20MeasurementSystemAnalysisGageR&RObjective•EvaluateswhetherameasuringsystemforvariabledataisadequateReports•Repeatability•Amountofvariationduetogageandmethod•Reproducibility•Amountofvariationduetochangingoperators•%StudyVariation•Percentofobservedvariationthatisduetothemeasurementsystem•%Tolerance•ComparesthemeasurementsystemtothetoleranceStudyVar%StudyVar%ToleranceSourceStdDev(SD)(5.15*SD)(%SV)(SV/Toler)TotalGageR&R0.00892860.04598219.379.20Repeatability0.00828860.04268617.988.54Reproducibility0.00331970.0170967.203.42Appraiser0.00331970.0170967.203.42Part-To-Part0.04522580.23291398.1146.58TotalVariation0.04609870.237408100.0047.48NumberofDistinctCategories=7PROPRIETARY21MeasurementSystemAnalysisKappaTest