Six Sigma : Concept, Role in Quality, Implementation Techniques and Benefits

1. SIX SIGMA 6Ϭ
SUBJECT : PRODUCTION AND QUALITY
MANAGEMENT

2. CONTENTS
 SIX SIGMA : INTORDUCTION
 ROLE OF SIX SIGMA
 IMPLEMENTATION OF SIX SIGMA
 DMAIC Methodology
 DMADV Methodology
 SIPOC Methodology
 BENEFITS OF SIX SIGMA

3. Current
Leadershi
p
Challenge
s
Custom
er
Delight
Retainin
g
People
Manufacturin
g Cycle Time
Keeping
up with
Technolog
y
AdvancesReducin
g Costs
Respondin
g More
Quickly
Structuring
for
Flexibility
Growing
Oversea
s
Markets

4. SIX SIGMA: INTRODUCTION
 Business Improvement Approach
 Focus of Six Sigma1
 Reducing variability in key product quality
characteristics to the level at which failure or defects
are extremely unlikely
 Tasks through 6σ achieved in corporate business1:
 Improving quality critical for customers
 Reducing costs
Objectives of Six Sigma program: Enhanced
product quality, yield and cost – all of which, in
turn, improve customer satisfaction2

5. SIX SIGMA
Six Sigma is a set of process improvement techniques
and tools in statistical quality control, mainly applied to
make customer happier and increase profits

6. Nσ DPMO* YIELD
1σ 691462 30.8538
2σ 308538 69.1462
3σ 66807 93.3193
4σ 6210 99.3790
5σ 233 99.9767
6σ 3.4 99.9997
* Defects per Million
Oppurtunity
The term “Sigma (б)” refers to measure of
variation.

7. SIX SIGMA: HISTORY
Dr Mikel J Harry wrote a paper relating early failures to Quality
in 1986
Bill Smith introduced it at his workplace while working as an
engineer at Motorola,USA in 1986
Jack Welch made it central to his business strategy at
General Electric,USA in 1995 and made the concept was
popularized

8. Mumbai Dabbawala
That's too with limited
resources

9. Criterias for Applying Six
Sigma
 Project Impact on the bottom line : “$” Profit
 Justification to the Quality Gained
 Applications – Does it need the SIX SIGMA ?

10. GE Six Sigma Economics
$0
$500
$1,000
$1,500
$2,000
$2,500
1996 1998 2000 2002
6 Sigma Projest Success
Cost
Benefit

11. ROLE OF SIX SIGMA
 OBJECTIVES OF 6σ :
 Improve customer satisfaction
 Improve quality of product and service
 Reduce process cycle time
 Overall cost saving
 Development of Staff Skill
 Eliminating Waste or Defects
 WHERE 6σ IS USED
 Manufacturing and service industries
 Sales and marketing
 Accounting and financing

12. IMPLEMENTATION OF SIX
SIGMA
DMAIC DMADV
Six Sigma Methodology inspired by Deming's Plan-Do-
Check-Act Cycle
SIPOC

13. STEPS DEFINITION TOOLS USED
Define Define the problem or project goal that
needs to be addressed
•FMEA
•Process Flow Chart
•Value Added Flow Chart
Measure Measure the current performance in
various aspects. It is a data collection
step
•MSA
•SPC
•Histogram and Pareto
Chart
Analysis Analyse the process to determine root
causes of variation, poor
performance(defects)
• DoE
•Why-5
•Cause and Effect Diagram
Improve Improve process performance by
addressing and eliminating the root
causes
•5S
•TPM
•Kaizen
Control Control improved process and future
process performance
•Control Plan
•Standardized Work
•Check Sheet
•SPC
DMAIC

14. STEPS DEFINITION
Define Define design goals that are consistent with customer
demands and the enterprise strategy
Measure Measure and identify CTQs (characteristics that are Critical To
Quality), measure product capabilities, production process
capability, and measure risks.
Analysis Analyze to develop and design alternatives
Define Design an improved alternative, best suited per analysis in the
previous step
Verify Verify the design, set up pilot runs, implement the production
process and hand it over to the process owner(s)
DMADV
 The DMADV methodology, instead of the DMAIC methodology, should be
used when:
 A product or process is not in existence at your company and one needs
to be developed
 The existing product or process exists and has been optimized but still

15. SIPOC
 SIPOC is a high-level view of a process
 Lean – Six Sigma Approach

16. SIX SIGMA: BENEFITS
 Enhanced ability to provide value to customer
 Enhanced understanding of business processes
 Reduction of Waste
 Improved profit performance
 Make customer happier

17. Summary
 Dr. W. Edwards Deming proposed to eliminate slogans
and programs to improve quality, rather he advised to
work to improve the system and provide information on
that.1
 Six Sigma is the improvement process in which various
techniques and tools are used to decrease variability in
production and increase profit with statistical quality
control,
 DMAIC and DMADV are six sigma implementation
methodologies inspired by Sir Deming’s Plan-Do-Check-
Act cycle

18. Questions
 Explain Six Sigma and its objectives ?
 Enlist Six Sigma methodologies and explain
DMAIC ?

19. References
1. Douglas C. Montgomery, Introduction To Statistical Quality
Control, John Wiley & Sons, Fourth Edition, Pg. 23
2. Mikel J. Harry, The Nature of Six Sigma Quality, Motorola Inc.,
1986.