精益六西格玛基本知识培训

CSD精益六西格玛培训2010-3什么是六西格玛?一个统计学中的用来衡量过程能力的评估指标(6Sigma水平意味着一百万个机会中只有3.4个不良)一系列用来降低变异的经过证实是有效的工具和手段一个成功的企业战略(在通用公司、摩托罗拉、德州仪器和联合信号等公司)一个关于卓越运作的全面的方法论和哲学为什么99%还不够好•99%意味着:–每一个小时有20000封邮件丢失–大约每天会有15分钟饮用水不安全–每个星期有5,000不正确的外科手术–在主要的机场每天有两次飞机没有按时达到–每年有200,000例错误的处方–每个月有7个小时没有电起源于Toyota(丰田)公司被许多其他的日本工厂所采用很晚才被西方的制造业所发现JIT和精益生产的别名:Toyota(丰田)生产系统Just-In-Time(及时制)生产流动生产系统观点关注于浪费JIT(及时制生产)和精益生产的起源什么是精益六西格玛•六西格玛–减少波动•精益–降低复杂性–减少浪费我们为什么同时需要精益六西格玛•公司为什么存在–满足客户的需要•公司的使命–盈利现代企业面临的挑战•顾客的忠诚度和保持•顾客对周期时间的要求越来越短•不断下降的价格的压力:低成本•更低的资本投入•产能的提升六西格玛改善增值过程的质量精益六西格玛能带来什么#ofSteps±3s±4s±5s±6s193.32%99.379%99.976799.99966%761.6395.73399.83999.99761050.0893.9699.76899.99662025.0888.2999.53699.9932406.2977.9499.07499.9864OverallYieldvs.Sigma(DistributionShifted±1.5s)精益减少非增加价值步骤骤精益六西格玛改善过程DefineMeasureAnalyzeImproveControl从业务和客户的角度定义机会寻找对流程表现有最大影响的关键因素(关键lX’s)并确定根本原因理解流程及其表现为关键X制定改善方案实施改善方案和控制计划关键要素•机会识别和项目选择•项目支持•关卡评审定义项目章程项目识别和选择SIPOC澄清范围客户之声和企业之声关卡DefineMeasureAnalyzeImproveControl战略客户财务流程利益相关者分析沟通计划StakeholderAnalysisCustomerNeedsCCR/MeasurePriority•1•5LSLUSLStakeholderAnalysisCustomerNeedsCCR/MeasurePriority•1•5LSLUSLCustomerCustomerRequirementRequirementKeyCustomerKeyCustomerIssueIssueCustomerCustomerCommentCommentCustomerCustomerRequirementRequirementKeyCustomerKeyCustomerIssueIssueCustomerCustomerCommentCommentTheformtakeslessthanfiveminutestocompleteTakestoolonglongtofillitout“Ihatefillingoutthisform.”Ambiguousinstructions“Idon’tunderstandthisjargon.”99%ofallformsfilledoutarecompletedcorrectlythefirsttime(nodefects)将VOC转化为需求StakeholderCommunicationObjectiveDesiredResponseWhatDoTheyAlreadyKnow?CurrentAttitudesCommunicationsChannelTimingWhoPreparesandDeliversCommunicationsPlanStakeholderCommunicationObjectiveDesiredResponseWhatDoTheyAlreadyKnow?CurrentAttitudesCommunicationsChannelTimingWhoPreparesandDeliversCommunicationsPlan团队启动SupplierInputsProcessOutputsCustomerIPOInputOutput实施测量Process•BasedonprocessandY=f(X)抽样策略和数据收集计划过程能力关卡验证测量系统Misc:Tolerance:Reportedby:Dateofstudy:Gagename:0550450350250321XbarChartbyOperatorSampleMeanMean=406.2UCL=555.8LCL=256.504003002001000321RChartbyOperatorSampleRangeR=146.3UCL=376.5LCL=0321490440390340PartOperatorOperator*PartInteractionAverage123321600500400300200OperatorByOperator321600500400300200PartByPart%Contribution%StudyVarPart-to-PartReprodRepeatGageR&R100500ComponentsofVariationPercentGageR&R(ANOVA)forResponse测量阶段价值流图Parameters:sSamplingFromaPopulationEntirePopulationofDataSampleStatisticalInferenceStatistics:X,S,etc.AnalysisParameters:sSamplingFromaPopulationEntirePopulationofDataSampleStatisticalInferenceStatistics:X,S,etc.AnalysisWastefulEnergyHabitsWeek1Week2Week3TotalLongshowers6Lightslefton11Windowsleftopen3ACsetbelow72o5Doorleftopen13Total15121138WastefulEnergyHabitsWeek1Week2Week3TotalLongshowers6Lightslefton11Windowsleftopen3ACsetbelow72o5Doorleftopen13Total151211381OrderMgmtSupervisorOrderMgmtSupervisorCUSTOMERCUSTOMERDISTDISTOrderMgmtOrderMgmtOrderMgmtOrderMgmtOrderMgmtOrderMgmtOrderMgmtOrderMgmtScreenforAcctMgrOrderMgmtScreenforAcctMgrOrderMgmtP/T=2minErrorRate=2%Volume=800P/T=6MinErrorRate=0%Volume=800P/T=6MinErrorRate=2%Volume=800P/T=2MinErrorRate=1%Volume=80020Orders3minPhoneCallLargeBusinessHomeSmallBusinessCustomerInfo44ProductNeed44Pricing44ShippingInfo44P/T=3minLostcalls=10%Volume=1200PickPack&ShipP/T=120MinErrorRate=1%Volume=120010102min6min6min2min120min240min5minCustomercalltime=24minServiceleadtime=384minCustomercalltime=24minServiceleadtime=384minSUPPLIERSSUPPLIERS2-5days2-5daysManualUpdateWeeklyUpdatePhoneCall1.Determinenumberofdefectopportunitiesperunit2.Determinenumberofunitsprocessed3.Determinetotalnumberofdefectsmade4.CalculateDefectsperOpportunity5.CalculateDPMO6.LookuptheSigmaintheSigmaTable(nextslide)O=N=D=DPO=DNxODPMO=DPOx1,000,000=SigmaQualityLevel==3100190.06363,333~3西格玛质量水平DefineMeasureAnalyzeImproveControl增值分析C&E矩阵根本原因分析数据分析关卡X’s优先化关键X’s以及根本原因回归分析阶段识别&完成快速定位1.Slkfdlfjdlfjflfjldsjflsjfds2.Slfjldskjfldjfldsjflds3.Dlfjldsjldsjfldsjf4.Dsfldsjfldsjfldsjfds5.Dsfjdsljfldsjfldsjf6.Dsfljfljfljflds7.Fjldjfldsjfdsf8.Dsfjdsfjdsf9.Dsfdsljfdsjfldsj10.slfjlsjfkds确定关键X’sArriveatscheduledtimeArrivewithproperequipmentDressedproperlyDeliveredviacorrectmodeTakebacktoroompromptlyProcessOutputs54424ImportanceProcessStep-----Processinput--------------CorrelationofInputtoOutput------------------Total---------PatientScheduled5203039AttendantAssigned5000025AttendantArrives5000025ObtainsEquipment1501027TransportPatient5000025ProvideTherapy000000NotifiesofReturn0000520AttendantAssigned0000520AttendantArrives0000520PatientReturned000052000000000000000232221201918171615141325201510MeanRater3232221201918171615141325201510MeanRater4131415161718192021222310152025MeanRater1232221201918171615141325201510MeanRater2Two-SampleT-TestandCI:Supp1,Supp2Two-sampleTforSupp1vsSupp2NMeanStDevSEMeanSupp1100599.5480.6190.062Supp2100600.231.870.19Difference=muSupp1-muSupp2Estimatefordifference:-0.68295%CIfordifference:(-1.073,-0.291)T-Testofdifference=0(vsnot=):T-Value=-3.46P-V