Six Sigma Phase I Review

CTX Tree (Process Tree)
...
Process Input
Critical to Process (CTP)
Product Quality
...
CTQ The CT Matrix Structure
Applying PTAR to Black Belt Development
Breakthrough Technologies for Success
Lower Spec Target Upper Spec

Continuously…...

Improve yields Eliminate defects


Reduce the cost of poor quality and
Reduce cycle time
Lower Control
Process Center
3.4
0.001
Short Term / Long Term
m
Six Sigma Centered Short Term
Zst = 6.0 DPPMst = .002
.001 ppm T ± 6s m
.001 ppm
LSL
USL
Six Sigma Shifted 1.5s Long Term Zlt = 4.5 DPPMlt = 3.4
2 3
Design
?
1 2
Material
$
Measurement System
Process Capability
1 2 3
3
1
3
2
Sigma Scale
(Distribution Shifted 1.5s) Defects
Z
2
3 4 5
PPM
308,537
66,807 6,210 233
6
7.5
Process Mapping Steps (cont.)
5. CLASSIFY
THE PARAMETERS
Classify the process parameters identified (in #4 above) into the following categories:
N = Noise Factors - Uncontrollable - May be controllable, but are not controlled by decision. C = Controllable factors - Process factors that can be changed to see the effect on product characteristics. S = Standard Operating Procedures - A procedure is used to define and run those factors. Tooling, Fixtures. Cr = Critical Factors - Determined through FMEA, DOE, etc.
Management Coordination Meeting
Optional Pre-training (2-3 days)
T rain
Kickoff (1 week)
Measure training (1 week)
Measure application (3 weeks)
Analyze training (1 week) Analyze application (3 weeks)

X1 . . . XN Independent Input-Process Cause Problem Control
The output is used to evaluate the process.
If our processes to produce X is so good, why are we constantly inspecting Y?

Man (People)
Machine (Equipment)
Method (Procedures) Material Measurement
Legend C Controllable Cr Critical N Noise P Procedure
Product Parameters, y’s
Characteristic 1
Operation 1
Tool A
Y = f (X)
CTQ
= Leverage Point
CTS, CTQ, CTP Relationships
CTY Tree
Critical to Satisfaction (CTS) Business Success Critical to Quality (CTQ) Customer Satisfaction
Quantifying the Normal Distribution
Definitions
m-3s m-2s m-1s
m
m+1s m+2s m+3s
68.26% 95.46% 99.73%
The Standard Normal Transform
Definitions
Z
X -m
s
Permits conversion of any data point (X) into a Z value. This value allows us to look up the percentage of the population that is above and below the data point.
Six Sigma is a measurement of how effective strategies are in eliminating defects and variations from processes and services to increase yield.

=
Y = F(x1,
What is Six Sigma?
Six Sigma, a Strategy and a Measurement of Strategies

Six Sigma is an overall strategy to accelerate improvements in processes and services (create breakthrough).
Mother Nature (Environment)
Why List the Parameters?
Process Mapping
Undr
Number of Darts
Professional
SL SL
SL
SL
-6 -5 -4 -3 -2 -1
1 2 3 4
5
6
distance from centre
Sources of Variation
Order Forms
Code
1
Define Measure Analyze Improve Control
P lan
Management Coordination Meeting
Management Coordination Meeting
Management Coordination Meeting
Management Coordination Meeting
Select the appropriate process level.
Product and Process Parameters Process Mapping
Inputs
STEP OF PROCESS
Process Parameters, x’s
Outputs
y = f(x)
Remember the 6 M’s
Realization Review after completion of project
Fundamentals of Process Mapping
Process Mapping A process map… Should describe the: ◦ Major activities / tasks ◦ Subprocesses ◦ Process boundaries ◦ Inputs ◦ Outputs ◦ Process Parameters ◦ Customers & Suppliers ◦ Process owners Should be reviewed frequently. Should document how the process actually operates, not how it is supposed to operate. (“As is”, not “To Be”) Will identify opportunities for quality improvements.
Characteristic 1 Characteristic 2 Characteristic 3 Characteristic 2 Characteristic 3
Operation 2 Operation 3
Process C
Process B
Factor
Tool B
Tool C
CTP
Process A
Data Types Definitions
Attribute Yes - no Good - bad Accept - reject Discrete Multiples of whole units Can not be meaningfully divided Count or classification Continuous Can be meaningfully divided into finer and finer increments of precision weight, length, voltage, time