introduction_to_six_sigma_2

KCtKeyConceptsCOPQ(CostofPoorCOPQ(CostofPoorQuality)-InspectionTraditionalQualityCosts:-Tangible-Warranty-Scrap-Rework-Rejects-MoreSetupsHiddCt-EasytoMeasure-LostOpportunities-MoreSetups-ExpeditingCosts-LostSales-LateDelivery-LostCustomerLoyaltyHiddenCosts:-Intangible-DifficulttoMeasureLostOpportunities-TheHiddenFactory-LostCustomerLoyalty-ExcessInventory-LongCycleTimes-CostlyEngineeringChangesAverageCOPQapproximately15%ofSalesCOPQv/sSigma50%QgLevel40%45%50%Sales25%30%35%ality%S10%15%20%5%tofQua0%5%10%23456Cost23456SigmaLevelCTQ(Critical-To-CTQ(CriticalToQuality)•CTQcharacteristicsfortheprocess,serviceorprocessp•Measureof“WhatisimportanttoCustomer”•6SigmaprojectsaredesignedtoimproveCTQpQ•Examples:–WaitingtimeinclinicWaitingtimeinclinic–Spellingmistakesinletter–%ofvalvesleakinginoperation%ofvalvesleakinginoperationDefectiveandDefectDefectiveandDefect•Anonconformingunitisadefectiveunit•Anonconformingunitisadefectiveunit•Defectisnonconformanceononeofmanyibllithtitifitthtpossiblequalitycharacteristicsofaunitthatcausescustomerdissatisfaction.•Adefectdoesnotnecessarilymaketheunitdefective•Examples:–ScratchonwaterbottleScatcoatebotte–(Howeverifcustomerwantsascratchfreebottle,thenthiswillbedefectivebottle))DefectOpportunityDefectOpportunity•CircumstancesinwhichCTQcanfailto•CircumstancesinwhichCTQcanfailtomeet.•Numberofdefectopportunitiesrelateto•Numberofdefectopportunitiesrelatetocomplexityofunit.•ComplexunitsGreateropportunitiesof•Complexunits–Greateropportunitiesofdefectthansimpleunits•Examples:•Examples:–Aunitshas5parts,andineachpartthereare3opportunitiesofdefects–Totaldefectopportunitiesoppotutesodeectsotadeectoppotutesare5x3=15DPO(DefectPerDPO(DefectPerOpportunity)Nmberofdefectsdiidedbnmberofppy)•Numberofdefectsdividedbynumberofdefectopportunities•Examples:–Inpreviouscase(15defectopportunities)if10unitsInpreviouscase(15defectopportunities),if10unitshave2defects.–Defectsperunit=2/10=0.2p–DPO=2/(15x10)=0.0133333DPMO(DefectPerMillion(Opportunities)DPOmltipliesbonemillion•DPOmultipliesbyonemillion•Examples:p–Inpreviouscase(15defectopportunities),if10unitshave2defects.–Defectsperunit=2/10=0.2–DPO=2/(15x10)=0.0133333–DPMO=0.013333333x1,000,000=13,333SixSigmaperformanceis3.4DPMO13,333DPMOis3.7SigmaYieldYieldProportionofnitsithinspecification•Proportionofunitswithinspecificationdividedbythetotalnumberofunits.•Examples:–If10unitshave2defectivesIf10unitshave2defectives–Yield=(10–2)x100/10=80%•RolledThroughYield(RTY)•RolledThroughYield(RTY)–Y1xY2xY3x…….xYnEg090x099x076x080=054–E.g0.90x0.99x0.76x0.80=0.54