福特汽车培训材料——6sigma推行
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It is not about theory, it’s about action.
精品资料网 15
Six Sigma Focus
Delighting the customer through flawless execution
Rapid breakthrough improvement Advanced breakthrough tools that work Positive and deep culture change Real financial results that impact the bottom
Crosby
Crosby taught: • Customer requirement is performance standard • Quality maturity is a journey • Preventive action as basic approach
精品资料网 8
精品资料网 3
Deming
Deming taught:
• Importance of understanding variation in work processes
• Role of management in leading for quality • Application of statistics • Plan-Do-Check-Act
Six Sigma - Performance Target
Sigma
3 Sigma
Long-Term Yield
93.32 %
Standard
Historical
4 Sigma
99.379 %
Current
5 Sigma
99.9767 %
Intermediate
6 Sigma
99.99966 %
Six Sigma
By Daniel Wu Ford Lio Ho Motor Company
精品资料网 1
Outline
Quality level What is Six sigma? Why we need Six sigma? Development and Deployment strategy How Six sigma merges into our daily
精品资料网 4
Deming’s Contribution to Profitability
CUSTOMER SATISFACTION
-Compete with value
MARKET SHARE
QUALITY
-Better products & services -Improved processes
Plan Do Act Check
PRODUCT QUALITY
-Reduce scrap -Increase product life -Eliminate incoming testing
PROCESS QUALITY
-Reduce rework -Eliminate in-process inspection
精品资料网
10
What Are the Limits to Improvement?
Basic Tools Wall
Design Wall
Clean Sheet
Design for Six Sigma (DFSS)
Statistical Tools
Basic Quality Tools
Juran
Juran taught: • Breakthrough performance • Pareto effect • Importance of management principles • Quality by design and planning
精品资料网 6
4
6,210
5
233
6
3.4
PPM
Defects per Million Opp.
Sigma is a statistical unit of measure that reflects process capability. The sigma scale of measure is perfectly correlated to
Region of Customer Complaints
Cos t
Region of
Questionable Performance
Region of
Questionable Performance
Lower Specification Limit Nominal Value
Upper Specification Limit
精品资料网 12
Change
“People do not resist change, people resist being changed.”
Beckhard
“It is not the strongest that survive, nor the fittest,
2 Sigma 3 Sigma 4 Sigma 5 Sigma
精品资料网
6 Sigma
11
Challenge in the millennium
Question confronting business leaders and managers: It is not: “How do we succeed?” It’s: “How do we stay successfully?”
Technical resistance Political resistance Organizational resistance Individual resistance
精品资料网 14
Six Sigma?
Six Sigma is not a business fad tied to a single method or strategy, but rather a flexible system for improved business leadership and performance.
EXTERNAL INTERNAL
PRODUCTIVITY
-Decreased cycle time -Eliminate set-up times
PRICE
-Compete with Price
COST
-Opportunity for profit
PROFIT
精品资料网 5
such characteristics as defects-per-unit, parts-per million defective, and the probability of a failure/error
Six Sigma corwrewswp.ocnndsshtuo.pcanrts p精er品bil资lion料if网process is centered
Juran’s Contribution
Planning 40
Control
Sporadic spike from observed problem
Special cause variation Common cause variation
Cost of Poor Quality
(Percent of operating costs) Production Begins
business?
精品资料网 2
Overview-Four Quality Gurus
Historically companies have focused on quality issues for customer satisfaction
Prior to six sigma there were four key quality gurus that most companies’ quality programs followed Deming Juran Crosby Taguchi
Defects Per Million Opportunity Reduced Cost of Poor Quality (COPQ) Improved Capacity and Productivity
$$’s
精品资料网
The Strategy
LSL
USL
T
LSL
USL
line
Passion + Execution = Fast and Lasting Results 精品资料网
Six Sigma - Goal
s
Process Capability
(Distribution Shifted ±1.5s)
2 308,537
3 66,807
SERVICE
DESIGN
ADMIN. QA
6 Sigma Methods
ENG PURCH.
MAINT.
MFG..
Hale Waihona Puke As long as there is a process that produces an output whether it is a manufactured product, data, an invoice, etc... we can apply the Six Sigma
Taguchi
Taguchi taught:
• Cost of poor quality is loss to society as a whole
• Robust quality is designed for consistent production
• Design control is more important than production control
but those most able to adapt to change.”
Charles Darwin The Origin of Species
精品资料网 13
Challenge
Resistance-the universal reaction to change.
精品资料网 9
Taguchi’s Contribution
Region of Customer Complaints
Lower Control
Limit
Mean
Upper Control
Limit
Region of Desired Performance
Region of Specified Performance
Breakthrough Strategy. For these processes to perform to a customer
swtawnwd.acrndsthheuy.rcenquir精e c品orr资ec料t in网puts!!!
Original zone of process control
20
Chronic Waste (an opportunity for improvement)
Improvement
Control
0 0
Time
New zone of process control
www.cLnessshoun.scLnearne精d 品资料网 7
Long-term
精品资料网
A Problem Solving Methodology
.... To Produce
Reduced Variation In Our Processes / Products Improved Rolled Throughput Yield, Defects Per Unit, &
T
• Characterize • Optimize
LSL
USL
T LSL’
USL’
• Breakthrough
Customer Focused - Both Internally & Externally 精品资料网
Which Business Function Needs It?
精品资料网 15
Six Sigma Focus
Delighting the customer through flawless execution
Rapid breakthrough improvement Advanced breakthrough tools that work Positive and deep culture change Real financial results that impact the bottom
Crosby
Crosby taught: • Customer requirement is performance standard • Quality maturity is a journey • Preventive action as basic approach
精品资料网 8
精品资料网 3
Deming
Deming taught:
• Importance of understanding variation in work processes
• Role of management in leading for quality • Application of statistics • Plan-Do-Check-Act
Six Sigma - Performance Target
Sigma
3 Sigma
Long-Term Yield
93.32 %
Standard
Historical
4 Sigma
99.379 %
Current
5 Sigma
99.9767 %
Intermediate
6 Sigma
99.99966 %
Six Sigma
By Daniel Wu Ford Lio Ho Motor Company
精品资料网 1
Outline
Quality level What is Six sigma? Why we need Six sigma? Development and Deployment strategy How Six sigma merges into our daily
精品资料网 4
Deming’s Contribution to Profitability
CUSTOMER SATISFACTION
-Compete with value
MARKET SHARE
QUALITY
-Better products & services -Improved processes
Plan Do Act Check
PRODUCT QUALITY
-Reduce scrap -Increase product life -Eliminate incoming testing
PROCESS QUALITY
-Reduce rework -Eliminate in-process inspection
精品资料网
10
What Are the Limits to Improvement?
Basic Tools Wall
Design Wall
Clean Sheet
Design for Six Sigma (DFSS)
Statistical Tools
Basic Quality Tools
Juran
Juran taught: • Breakthrough performance • Pareto effect • Importance of management principles • Quality by design and planning
精品资料网 6
4
6,210
5
233
6
3.4
PPM
Defects per Million Opp.
Sigma is a statistical unit of measure that reflects process capability. The sigma scale of measure is perfectly correlated to
Region of Customer Complaints
Cos t
Region of
Questionable Performance
Region of
Questionable Performance
Lower Specification Limit Nominal Value
Upper Specification Limit
精品资料网 12
Change
“People do not resist change, people resist being changed.”
Beckhard
“It is not the strongest that survive, nor the fittest,
2 Sigma 3 Sigma 4 Sigma 5 Sigma
精品资料网
6 Sigma
11
Challenge in the millennium
Question confronting business leaders and managers: It is not: “How do we succeed?” It’s: “How do we stay successfully?”
Technical resistance Political resistance Organizational resistance Individual resistance
精品资料网 14
Six Sigma?
Six Sigma is not a business fad tied to a single method or strategy, but rather a flexible system for improved business leadership and performance.
EXTERNAL INTERNAL
PRODUCTIVITY
-Decreased cycle time -Eliminate set-up times
PRICE
-Compete with Price
COST
-Opportunity for profit
PROFIT
精品资料网 5
such characteristics as defects-per-unit, parts-per million defective, and the probability of a failure/error
Six Sigma corwrewswp.ocnndsshtuo.pcanrts p精er品bil资lion料if网process is centered
Juran’s Contribution
Planning 40
Control
Sporadic spike from observed problem
Special cause variation Common cause variation
Cost of Poor Quality
(Percent of operating costs) Production Begins
business?
精品资料网 2
Overview-Four Quality Gurus
Historically companies have focused on quality issues for customer satisfaction
Prior to six sigma there were four key quality gurus that most companies’ quality programs followed Deming Juran Crosby Taguchi
Defects Per Million Opportunity Reduced Cost of Poor Quality (COPQ) Improved Capacity and Productivity
$$’s
精品资料网
The Strategy
LSL
USL
T
LSL
USL
line
Passion + Execution = Fast and Lasting Results 精品资料网
Six Sigma - Goal
s
Process Capability
(Distribution Shifted ±1.5s)
2 308,537
3 66,807
SERVICE
DESIGN
ADMIN. QA
6 Sigma Methods
ENG PURCH.
MAINT.
MFG..
Hale Waihona Puke As long as there is a process that produces an output whether it is a manufactured product, data, an invoice, etc... we can apply the Six Sigma
Taguchi
Taguchi taught:
• Cost of poor quality is loss to society as a whole
• Robust quality is designed for consistent production
• Design control is more important than production control
but those most able to adapt to change.”
Charles Darwin The Origin of Species
精品资料网 13
Challenge
Resistance-the universal reaction to change.
精品资料网 9
Taguchi’s Contribution
Region of Customer Complaints
Lower Control
Limit
Mean
Upper Control
Limit
Region of Desired Performance
Region of Specified Performance
Breakthrough Strategy. For these processes to perform to a customer
swtawnwd.acrndsthheuy.rcenquir精e c品orr资ec料t in网puts!!!
Original zone of process control
20
Chronic Waste (an opportunity for improvement)
Improvement
Control
0 0
Time
New zone of process control
www.cLnessshoun.scLnearne精d 品资料网 7
Long-term
精品资料网
A Problem Solving Methodology
.... To Produce
Reduced Variation In Our Processes / Products Improved Rolled Throughput Yield, Defects Per Unit, &
T
• Characterize • Optimize
LSL
USL
T LSL’
USL’
• Breakthrough
Customer Focused - Both Internally & Externally 精品资料网
Which Business Function Needs It?