6 Sigma Introduction 共80页
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It is potentially controllable variation with the existing technology.
It presents how the process is actually performing over time. (Sustained process capability)
technology.
6σ/ Maggie Tsao 13
Yield -- 1.5 Sigma Shift
6σ/ Maggie Tsao 14
Defect% -- Normal Distribution
6σ/ Maggie Tsao 15
Defect% -- Centered Distribution
Application of statistical tools to Define/ measure/ analyze/ improve/ control
6σ/ Maggie Tsao 5
Yield -- Normal Distribution
LSL
68.27% 95.45% 99.73% 99.994% 99.99994% 99.9999998%
6σ/ Maggie Tsao 16
Defect% -- 1.5Sigma Shift
6σ/ Maggie Tsao 17
Centered vs. 1.5 Sigma Shift
6σ/ Maggie Tsao 18
What’s DPU ???
Defects Any variation of a required characteristic of product or
A vision and philosophy of data based decision making, and a commitment to improved customer quality.
A measurement of our product and process capability. The objective is 3.4 defects per million opportunities. Z LT = 4.5 Z ST = 6.0
Long Term Capability
ZST is a measure of
ZLT is a measure of
technological capability. technology and control.
ZST is calculated assuming the process is centered on the target.
executive Art Sundry stood up and proclaimed, “ The real problem at Motorola is that our quality stinks!” •In 1984, Dr. Mikel Harry at Motorola’s Government Electronics Group, began to experiment with problem solving through statistical analysis and finally formulated a method for applying 6 sigma throughout the company • In 1988, Motorola won the coveted prize of the Malcolm Baldrige National Quality Award as the result of achieving tenfold improvement over a five year period.
6σ/ Maggie Tsao 3
What’s 6 Sigma
Contents
• What’s 6 Sigma
•Why 1.5 Sigma Shift? •Why 3.4ppm ? • DPU & DPMO • 6 Sigma Goal
6σ/ Maggie Tsao 4
What’s 6 Sigma
6σ/ Maggie Tsao 2
6 Sigma History (II)
•In 1991, applying 6 sigma in early design stage, Bandit pager was designed to be produced in its automated factory in BB within 72 min. from the time the order was placed in any sales office. •In 1993, Dr. Mikel Harry left Motorola and join in ABB, with the shift of defect controlling focus to reducing costs, the ABB achieved a 68 percent reduction in defect levels and a 30% reduction product costs, resulting in an $898M savings/cost reduction each year over a two-year period. • In 1994, Dr. Harry opened the doors to the 6 sigma academy in Scottsdale, Arizona, taking on General Electric and AlliedSignal as the first clients. Within a short time, 6 sigma began to spread like wildfire to other industries
service, which is far enough removed from its target value to prevent the product or service from fulfilling the physical and functional requirements of the customer.
Short Term Variation (Common Cause) Within Subgroups
6σ/ Maggie Tsao 9
Common Cause Variation
Variation present in every process. Also known as residual or background noise.
σ LT present the assignable cause (long term) variation
and will use ZLT to present long term capability.
6σ/ Maggie Tsao 11
Why 1.5 Sigma Shift? (I)
Short Term Capability
It is variation that cannot be controlled with the existing technology.
It present the best the process can be with the present technology. (Inherent process capability)
6σ/ Maggie Tsao 20
DPU Case Study (II)
Function : Security Product or Service : Package inspection at front door Defect : Package not inspected Unit : Each person # of Defects : 380 # of Units : 10,000 DPU : 380/10,000 or 0.38
USL
1
-66σ 1-15σ -146σ -231σ -22σ6 -13σ1 03σ6 1σ41 2σ46 3σ51 4σ56 5σ61 6σ 66 71
6σ/ Maggie Tsao 6
How to Calculate Yield ? (I)
6σ/ Maggie Tsao 7
Yield -- Centered Distribution
A Unit • Is the measure of volume of output from your area. • Is observable and countable.
Defects Per Unit
Number of Defects Found at Any Review Point Number of Units Processed Through That Review Point
• In 1990, Harry started up and lead Motorola’s 6 sigma research institute in Schaumburg which was funded by Motorola, IBM, TI, ABB, Kodak, and Digital Electronics.
6σ/ Maggie Tsao 8
Variation is Nature
Sub-group 1
Sub-group 2Fra bibliotekSub-group 4 Sub-group 3
Sub-group 5
Long Term Variation (Assignable Cause) Between Subgroups
Time
6σ/ Maggie Tsao 19
DPU Case Study (I)
Function : Customer Service Product or Service : Hot line response Defect : Not answered within 5 rings Unit : Each phone call # of Defects : 46 # of Units : 2,000 DPU : 46/2,000 or 0.023
σ ST present the common cause (short term) variation
and will use ZST to present short term capability.
6σ/ Maggie Tsao 10
Assignable Cause Variation
Variation present the outside influences on a process that cause it to shift and drift. Also known as special cause variation.
6σ/ Maggie Tsao 12
Why 1.5 Sigma Shift? (II)
“6 σ” means:
ZST = 6.0 and Cp = 2.0 ZLT = 4.5 and Cpk = 1.5
ZSHIFT = ZST – ZLT ZSHIFT represents the ability to CONTROL the
6 Sigma Introduction
Contents
• 6 Sigma History •What’s 6 Sigma? • 6 Sigma Methodology • 6 Sigma Tools Quick View
6σ/ Maggie Tsao 1
6 Sigma History (I)
• The guest to achieve 6 sigma had its birth at Motorola in 1979 when
ZST is calculated using the measured mean of the data.
Goal: ZST = 6.0
Goal: ZST = 4.5
Entitlement-the best the Actual Process Performance process can be
It presents how the process is actually performing over time. (Sustained process capability)
technology.
6σ/ Maggie Tsao 13
Yield -- 1.5 Sigma Shift
6σ/ Maggie Tsao 14
Defect% -- Normal Distribution
6σ/ Maggie Tsao 15
Defect% -- Centered Distribution
Application of statistical tools to Define/ measure/ analyze/ improve/ control
6σ/ Maggie Tsao 5
Yield -- Normal Distribution
LSL
68.27% 95.45% 99.73% 99.994% 99.99994% 99.9999998%
6σ/ Maggie Tsao 16
Defect% -- 1.5Sigma Shift
6σ/ Maggie Tsao 17
Centered vs. 1.5 Sigma Shift
6σ/ Maggie Tsao 18
What’s DPU ???
Defects Any variation of a required characteristic of product or
A vision and philosophy of data based decision making, and a commitment to improved customer quality.
A measurement of our product and process capability. The objective is 3.4 defects per million opportunities. Z LT = 4.5 Z ST = 6.0
Long Term Capability
ZST is a measure of
ZLT is a measure of
technological capability. technology and control.
ZST is calculated assuming the process is centered on the target.
executive Art Sundry stood up and proclaimed, “ The real problem at Motorola is that our quality stinks!” •In 1984, Dr. Mikel Harry at Motorola’s Government Electronics Group, began to experiment with problem solving through statistical analysis and finally formulated a method for applying 6 sigma throughout the company • In 1988, Motorola won the coveted prize of the Malcolm Baldrige National Quality Award as the result of achieving tenfold improvement over a five year period.
6σ/ Maggie Tsao 3
What’s 6 Sigma
Contents
• What’s 6 Sigma
•Why 1.5 Sigma Shift? •Why 3.4ppm ? • DPU & DPMO • 6 Sigma Goal
6σ/ Maggie Tsao 4
What’s 6 Sigma
6σ/ Maggie Tsao 2
6 Sigma History (II)
•In 1991, applying 6 sigma in early design stage, Bandit pager was designed to be produced in its automated factory in BB within 72 min. from the time the order was placed in any sales office. •In 1993, Dr. Mikel Harry left Motorola and join in ABB, with the shift of defect controlling focus to reducing costs, the ABB achieved a 68 percent reduction in defect levels and a 30% reduction product costs, resulting in an $898M savings/cost reduction each year over a two-year period. • In 1994, Dr. Harry opened the doors to the 6 sigma academy in Scottsdale, Arizona, taking on General Electric and AlliedSignal as the first clients. Within a short time, 6 sigma began to spread like wildfire to other industries
service, which is far enough removed from its target value to prevent the product or service from fulfilling the physical and functional requirements of the customer.
Short Term Variation (Common Cause) Within Subgroups
6σ/ Maggie Tsao 9
Common Cause Variation
Variation present in every process. Also known as residual or background noise.
σ LT present the assignable cause (long term) variation
and will use ZLT to present long term capability.
6σ/ Maggie Tsao 11
Why 1.5 Sigma Shift? (I)
Short Term Capability
It is variation that cannot be controlled with the existing technology.
It present the best the process can be with the present technology. (Inherent process capability)
6σ/ Maggie Tsao 20
DPU Case Study (II)
Function : Security Product or Service : Package inspection at front door Defect : Package not inspected Unit : Each person # of Defects : 380 # of Units : 10,000 DPU : 380/10,000 or 0.38
USL
1
-66σ 1-15σ -146σ -231σ -22σ6 -13σ1 03σ6 1σ41 2σ46 3σ51 4σ56 5σ61 6σ 66 71
6σ/ Maggie Tsao 6
How to Calculate Yield ? (I)
6σ/ Maggie Tsao 7
Yield -- Centered Distribution
A Unit • Is the measure of volume of output from your area. • Is observable and countable.
Defects Per Unit
Number of Defects Found at Any Review Point Number of Units Processed Through That Review Point
• In 1990, Harry started up and lead Motorola’s 6 sigma research institute in Schaumburg which was funded by Motorola, IBM, TI, ABB, Kodak, and Digital Electronics.
6σ/ Maggie Tsao 8
Variation is Nature
Sub-group 1
Sub-group 2Fra bibliotekSub-group 4 Sub-group 3
Sub-group 5
Long Term Variation (Assignable Cause) Between Subgroups
Time
6σ/ Maggie Tsao 19
DPU Case Study (I)
Function : Customer Service Product or Service : Hot line response Defect : Not answered within 5 rings Unit : Each phone call # of Defects : 46 # of Units : 2,000 DPU : 46/2,000 or 0.023
σ ST present the common cause (short term) variation
and will use ZST to present short term capability.
6σ/ Maggie Tsao 10
Assignable Cause Variation
Variation present the outside influences on a process that cause it to shift and drift. Also known as special cause variation.
6σ/ Maggie Tsao 12
Why 1.5 Sigma Shift? (II)
“6 σ” means:
ZST = 6.0 and Cp = 2.0 ZLT = 4.5 and Cpk = 1.5
ZSHIFT = ZST – ZLT ZSHIFT represents the ability to CONTROL the
6 Sigma Introduction
Contents
• 6 Sigma History •What’s 6 Sigma? • 6 Sigma Methodology • 6 Sigma Tools Quick View
6σ/ Maggie Tsao 1
6 Sigma History (I)
• The guest to achieve 6 sigma had its birth at Motorola in 1979 when
ZST is calculated using the measured mean of the data.
Goal: ZST = 6.0
Goal: ZST = 4.5
Entitlement-the best the Actual Process Performance process can be