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StatisticalTechniqueto6-SigmaQuality1ABOUTINSTRUCTORCurrentposition:Sr.Officer,LCMEng.Dept MPhif.(EE),BEng(Hons)Eng.Pastworkingexperience:HKUST:TofabricateOLEDanddesigntherelateddrivingcicruits.CityU:TofabricatePolymericOptoWaveguidesPhilips:TodevelopLCMincludingB/W,ColorSTN,TFTandPLEDSolomonSystech:TodevelopthedriverICforB/W,ColorSTN,TFTandPDAproducts.2COURSEABSTRACTThiscourseistointroducethewaysofProcessControlSystemtargetingto6-sigmaQualityinthemanufacturingareas.ThebenchmarkofSixSigmawillbesharedduringthecourse.Inordertoachieveit,seriesofmeasurementsystemcapabilities,performancemetricsandprocesscontrolmethodologywillbediscussed.3COURSEOBJECTIVES

Participantswilllearn:-*WhatissixSigma*ControlPlanningandMethodology*Measurementsystemcapability*ProcessCapabilityMetrics*ContinuousProcessImprovement4TraditionalProcessCapability*99.73%ofthetotalareawithinspec.limits.Defectratewillbe2,700PPM.*Only93.32%oftheareaunderthecurveanddefectrateis66,000PPM.5SixSigmaCapability*Defectrate-0.002PPM*Defectrate-3.4PPM6•

OutputVariablesManagetheoutputs.ATraditionalViewSalesGrowthMarketShareProfitability7•

OutputVariables•

InputVariablesManagetheinputs;respondtotheoutputs.ANon-traditionalViewSalesGrowthMarketShareProfitabilityCustomerSatisfactionProductQualityOn-TimeDeliveryCOQCreditTermsRelationshipsServiceCustomerTraining8Whatis6-SigmaMotorola’stermtoexpressaprocesscapabilitythatproducesonly0.002defectspereachmillionunitsmanufacturedwhentheprocessiscentered,oramaximumofonly3.4defectsforeachmillionunitswhentheprocessshiftsupto1.5sigmatooneside.Theterm“6sigma”isbecomingsynonymouswith“QualityExcellence”.9

TheConceptof"SixSigma"DifferentnumbersofOpportunities...ManufacturingProcessesCustomersorSuppliersAdministrativeAreas6=Astructuralapproachtocontinuousimprovement1-Identifytheproductorserviceyouprovide2-Identifyyourcustomers&theirrequirements3-Determineyourneeds&suppliers4-Definetheprocessfordoingwork5-Eliminatedefectsources/optimizetheprocess6-ContinuouslyimprovetheSigmalevel(or“Sixstepstowardexcellence”)

ABitofStatistics...-7.0-6.0-5.0-4.0-3.0-2.0-1.00.01.02.03.04.05.06.07.0upperspeclimitLowerspeclimit+1.5Sigma-1.5Sigma3.4ppm

orZero+10CENSOREDNormalDistribution-GaussianCurveSigma==Deviation(Squarerootofvariance)-7-6-5-4-3-2-101234567AxisgraduatedinSigma68.27%95.45%99.73%99.9937%99.999943%99.9999998%result:317300ppmoutside(deviation)45500ppm2700ppm63ppm0.57ppm0.002ppmbetween+/-1between+/-2between+/-3between+/-4between+/-5between+/-6=11SixSigma...AndtheStatistics

-7.0-6.0-5.0-4.0-3.0-2.0-1.00.01.02.03.04.05.06.07.0+1.5Sigma-1.5Sigma3.4ppmorZeroUpperspec.limitLowerspec.limitReducethevariation:when<=Designspecificationwidth/12Stabilizetheprocess,withoutaffectingthevariance,tolimitthemaximumprocessshiftto+/-1.5Undertheseconditions,andintheworstcase,therewillbenomorethana3.4ppmdefect(reject)level,withspecificationlimitsat4.5ononesideand7.5ontheother.Note:Onecanseethatthepointcorrespondingto6onthegraduatedperformancescaleaboveismeasuredin””Sigma’s”(with6correspondingtoa3.4ppmdefectlevel).Cp>=2andCpk>=1.5Cp>=212SixSigma...AndCapabilityCp=Designspecificationwidth63Cpk=Min.

Mean-SpecLimitWithamaximumprocessshiftof+/-1.513-CustomersorSuppliers:Oneopportunityperproductdeliveredorpercomponentpurchased.-Manufacturingprocess:Opportunitiesateachprocessstep)-Administrativeareas:NumberofopportunitiesforerrorforeachactivityperformedTheOpportunities...14SomeExamplesofOpportunityCustomerPerspective:1opportunityperproductdeliveredex.1regulator=1opportunity1controller=1opportunityProductionlines:Regulator=160opportunitiesController=1200opportunitiesForm(Payment,PurchaseOrder,..):NumberoffieldsExpedite/Delivery:1opportunity/packagingunit15Aqualitylevelof"6"correspondstolessthan3.4defectspermillionOpportunities(i.e.,correct99.99966%ofthetime)

NumberofDefectsNumberofUnits=

D.P.U

D.P.Ux1000000NumberofOpportunities

=D.P.M.Op.SigmaandOpportunities1Opportunity=D.P.M.Op16AUniversalMeasurementScale...345676681062102333.4SigmaDPMOpOnonecondition:Calculatethedefectsandestimatetheopportunitiesinthesameway...17MeasurementWithSIGMAIsSimple!!!EstimatetheOpportunitiesCountthe

DefectsFollowtheIndicator:DefectspermillionOpportunitiesConversioninto"Sigma"canbeaccomplishedwiththehelpofastatisticaltable.

6=3.4dpmo18ConvertingDefectLevelsto.....Sigma!175defectsareidentifiedwhileproducing5000controllersThemanufactureofonecontrollerallowsfor1367defectopportunities.D.P.Op=0.035/1367=0.0000256AnExample:D.P.U=175/5000=0.035

D.P.M.Op=25.6

"Sigma"level:5.5519SixSigma:AnAmbitiousObjective?•Accurateto99.99966%(lessthan3.4defectsforeachmillionopportunities)couldappearexcessive....!99.9%isalreadyVERYGOOD!Butwhatcouldhappenataqualitylevelof99.9%(i.e.,1000ppm),inoureverydaylives(about4.6)?•4000wrongmedicalprescriptionseachyear•Morethan3000newbornsaccidentallyfallingfromthehandsofnursesordoctorseachyear•TwolongorshortlandingsatAmericanairportseachday•400lettersperhourwhichneverarriveattheirdestination20TheImpactofQuality:““6SigmaSuppliers””13wrongdrugprescriptionsperyear10newbornbabiesdroppedbydoctors/nursesperyearTwoshortorlonglandingsperyearinalltheairportsintheU.S.Onelostarticleofmailperhour21DefectReduction:““PeelingtheOnion””•ActionNameDateACTIONPLANPROCEDURECONTINUOUSIMPROVEMENTMODELTRENDCHARTGOALTIME100%BRAINSTORMING/PARETOANALYSIS/ROOTCAUSEIDENTIFICATIONRESULTSANDINSTITUTIONALIZEMEASUREANALYZEPROBLEMSOLVEProcessstep1Processstep3Processstep2••••SUPPLIERSUPPLIERSUPPLIERCUSTOMERCUSTOMERCUSTOMERRECORDDEFECTSRECORDDEFECTSRECORDDEFECTSRECORDDEFECTSRECORDDEFECTS22MeasurementSystemsCapabilityThecapabilityofthemeasurementsystemmustbeensuredbeforethesystemisusedforprocesscontrolorformeasurementsusedincapabilitystudies.GageRepeatability&Reproducibility(R&R):isastatisticalstudytoinvestigatethegage’sabilitytorepeatameasurementonthesamepart(repeatability)andtheabilitytogivethesamereadingonthesamepartwhenusedbydifferentpeople(reproducibility).Under10%-acceptable10%-30%-Maybeacceptabledependingonapplication.Effortshouldbemadetoimprovethegagacapability.Over30%-Notsuitabletouse.23GageR&R24ProcessPerformanceCapabilityTomeasuretheabilityofamachineorprocesstoproduceaproductwithinspecification.PotentialProcessCapabilityIndex(Cp):-RatioofspecificationwidthovertheprocessspreadSpecWidthCp=ProcessSpreadUSL-LSL=6-Sigma25ProcessPerformanceCapabilityProcessCapabilityIndex(CpK):-anoff-targetprocessshouldbe““penalized”forshiftingfromwhereitshouldbe.CpKistheindextomeasurethisrealcapabilitywhentheoff-targetpenaltyistakenintoconsideration.Target-ProcessMeanPenalty/Correctionfactor,k=1/2SpecificationWidthMean-CloserspeclimitCpk=Cp(1-k)=3sigma26ProcessPerformanceCapability27ProcessPerformanceCapability*Maximumcustomersatisfactionisachievedonlywhentheproductisrightontarget.28ProcessPerformanceCapability29TotalProcessControlSystem1.Process/ProductFailureModeandEffectsAnalysis(FMEA)Ananalyticaltechniqueaimedatproblempreventionthroughidentificationofpotentialproblems.Foreachfailuremode,theeffectonthetotalsystemisstudiedandactionstominimizetheprobabilityoffailuresareplanned.FMEAwillserve:a)Identifiesknownorpotentialprocessfailuremodesb)Assessesthepotentialriskeffectsofthefailurestothecustomerc)Identifiesthepotentialproductormanufacturingprocesscausesandcontrolactionsd)Identifiessignificantprocessvariablestofocuscontrolsfordetectingandreducingsimilarfailures30FMEA31TotalProcessControlSystem2.ProcessControlPlanAsummarydescriptionoftheproceduresforcontrollingallsignificantcharacteristicsoftheprocessesusedtomanufactureafamilyofsimilarproducts.Itidentifiestheimportantprocessesusedtoproduceaproduct,thesignificantcharacteristicsassociatedwitheachprocessandhowtocontroleachofthosesignificantcharacteristics.ControlPlanconsists:a)Processb)Equipmentc)Significantcharacteristicsd)Measurementmethode)Minimumsamplesizeandfrequencyf)Analysismethodg)Outofcontrolaction32ControlPlan33TotalProcessControlSystem3.TotalControlMethodologyAsetofdocumentsprovidingallnecessaryinstructionsonhowtocontroleachsignificantvariableinaprocess.ATotalControlMethodologyisusedattheindividualprocesslevel,whileaControlPlanisusedforaproduct