S活动标准培训教程英文

6

Overview

SixSigma:-ADefinition-AppliedtoGE-GEQualityInitiative-WhyThisApproach?-OriginofSixSigma-The“BreakthroughStrategy”-ArrivingatSigmaSixSigmaStructureKeyConcepts&ToolsAPracticalExampleAnOverviewNotalotofDetails!!6

Overview

“SixSigma”

Ifwecan’texpresswhatweknowintheformofnumbers,wereallydon’tknowmuchaboutit.Ifwedon’tknowmuchaboutit,wecan’tcontrolit.Ifwecan’tcontrolit,weareatthemercyofchance.MikelJ.HarryPresident&CEOSixSigmaAcademy,Inc.ARigorousMethodforMeasuring&ControllingOurQuality“...willbringGEtoawholenewlevelofqualityinafractionofthe

timeitwouldhavetakentoclimbthelearningcurveonourown.”JohnF.Welch,Jr.1995GEAnnualReport6

Overview

WhatDoes“Sigma”Mean?

SigmaisaMeasureoftheConsistencyofaProcessIt(isAlsothe18thLetterintheGreekAlphabet!WhyDoesGENeedAQualityInitiative?GERaisingTheBarNewGoaltobe“BestintheWorld”vs.#1or#2CustomersareExpectingMore,weMustDeliver“Ship-and-fix”ApproachnoLongerToleratedintheMarketAimtoSpeedPastTraditionalCompetitorsin5YearsGoalConsistentwithReducedTotalCostsWeMustAcknowledgeOurVulnerabilitiesPoorQualityThatImpactsCustomersProblemswithNPITooHighInternalCosts6

Overview

WeNeedaMajorInitiativetoMoveFromWhereweAretoWhereweWanttobe6

Overview

WhyDoesGENeedAQualityInitiative?40%35%30%25%20%10%15%5%CostofFailure(%ofSales)DefectsperMillion3.4233621066,807308,537500,000Sigma654321

EstimatedCostofFailureinUSIndustryis15%ofSales;TakingGEFroma3toa6CompanyWillSave~$10.5BillionperYear!Why“SixSigma”?ProvenSuccessfulin“Quality-Demanding”Industriese.g.,Motorola,TexasInstruments(manyprocessstepsinseries)ProvenMethodtoReduceCostsHighlyQuantitativeMethod–ScienceandLogicInsteadofGutFeelIncludesManufacturing&Service(closetocustomer)andProvidesBridgetoDesignforQualityConceptsHasSupportandCommitmentofTopManagementItWorks!!!6

Overview

Sigma3456SpellingMoneyTime1.5

MisspelledWordsperPageinaBook1

MisspelledWordper30PagesinaBook1

MisspelledWordinasetofEncyclopedias1

MisspelledWordinalloftheBooksinaSmallLibrary$2.7MillionIndebtednessper$1BillioninAssets$570

Indebtednessper$1BillioninAssets$63,000

Indebtednessper$1BillioninAssets$2

Indebtednessper$1BillioninAssets31/2MonthsperCentury21/2DaysperCentury30MinutesperCentury6SecondsperCentury6

isSeveralOrdersofMagnitudeBetterThan3!!!Sigma:AMeasureofQuality6

Overview

WhereDoes“SixSigma”ComeFrom?

MikelJ.HarryoneoftheOriginalArchitectsPreviouslyHeadedQualityFunctionatABBandMotorola

NowPresident/CEOofSixSigmaAcademyinPhoenix,ArizonaHasConsultedforTexasInstruments,AlliedSignal(andothers)CurrentlyRetainedbyGEtoTeachtheImplementation,DeploymentandApplicationofSixSigmaConcepts&Tools

LearningfromThoseWhoHavehadSuccessWith6WillAccelerateitsImplementationatGE6

Overview

So...WhatisSixSigma?

AMeasurementSystem

AProblem-SolvingApproach

ADisciplinedChangeProcess“THESIXSIGMABREAKTHROUGHSTRATEGY”MeasureAnalyzeImproveControl6

Overview

How

DoWeArriveatSigma?Measuring&EliminatingDefectsisthe“Core”ofSixSigmaMeasurementSystemIdentifytheCTQsLookforDefectsinProductsorServices

“CriticaltoQuality”CharacteristicsortheCustomerRequirementsforaProductorService

CountDefectsorfailurestomeetCTQ

requirementsinallprocessstepsDefineDefectOpportunities

AnystepintheprocesswhereaDefectcouldoccurinaCTQ

ArriveatDPMO

UsetheSIGMATABLEConvertDPMOtoSigma

DefectsPerMillionOpportunities23456308,53766,8076,2102333.4PPM

DefectsperMillionofOpportunity

SigmaLevel6

Overview

MeasurementSystem23456308,53766,8076,2102333.4PPM

SIGMALEVEL

DEFECTSperMILLIONOPPORTUNITYIRSTaxAdviceBestCompaniesAirlineSafetyAverageCompanyGEAirlineBaggageDoctor’sPrescriptionRestaurantBills

AverageCompanyin3to4RangeSomeSigma“Benchmarks”6

Overview

MeasurementSystemAGraphic/QuantitativePerspectiveonVariationAverageValueManyDataSetsHaveaNormalorBellShapeNumberofPeopleArrivingatCRDTime7:007:157:307:458:008:158:308:459:009:156

Overview

ProblemSolvingApproachCenterProcessReduceSpreadXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXOff-TargetUnpredictableOn-Target

6HelpsusIdentifyandReduceVARIATIONdueto:-InsufficientProcessCapability-UnstableParts&Materials-InadequateDesignMarginTargetUSLLSLTargetUSLLSLTargetUSLLSLCenterProcessReduceSpreadOff-TargetUnpredictableOn-TargetDefects6

Overview

ProblemSolvingApproach“LowerSpecificationLimit”“UpperSpecificationLimit”LessVariationMeansFewerDefects&HigherProcessYields

6

Overview

ProblemSolvingApproachKeyComponentsof“BREAKTHROUGHSTRATEGY”MeasureAnalyzeImproveControl

IdentifyCTQ&CTP(CriticaltoProcess)VariablesDoProcessMappingDevelopandValidateMeasurementSystems

BenchmarkandBaselineProcessesCalculateYieldandSigmaTargetOpportunitiesandEstablish

ImprovementGoalsUseofParetoChart&FishboneDiagrams

UseDesignofExperimentsIsolatethe“VitalFew”fromthe“TrivialMany”SourcesofVariationTestforImprovementinCenteringUseofBrainstorming

andActionWorkouts

SetupControlMechanismsMonitorProcessVariationMaintain“InControl”ProcessesUseofControlChartsand

ProceduresAMixofConceptsandToolsWillAlsoIntegratewithNPIProcess6

Overview

DisciplinedChangeProcessANewSetofQUALITYMEASURES

CustomerSatisfactionCostofPoorQualitySupplierQualityInternalPerformanceDesignforManufacturability

WillApplytoManufacturing&Non-ManufacturingProcessesandbeTracked&ReportedbyEachBusiness6

Overview

StructureQualityCouncil

Members:Labs&Functions“Pipeline”&BBProjectPrioritiesTraining&CertificationMeasurements&RewardsCommunicationsChampions

Leadership:OverallInitiativeProjectFundingHR:Training&RewardsBlackBelts

Lead6ProjectTeams“Measure/Analyze”“Improve/Control”OutwithBusinessesHereatCRDMasterBlackBelts

Teach6

MentorBlackBeltsMonitorBBProjectsWork“Pipeline”ProjectsAResourcePoolTeamMembers

Learn/Use6ToolsWorkonBBProjectsPartofTheJobOutwithBusinesses6

ProjectswiththeGEBusinesses

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Dependent

Output

Effect

Symptom

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Independent

Input-Process

Cause

Problem

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Target-3

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Loss1

Loss3Rejects

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Yield

YieldNumberofOperationsNumberofOperations1.001.000.900.900.800.800.700.700.600.600.500.500.400.400.300.3000.100.000.001101001,00010,000100.0001,000,0001101001,00010,000100.0001,000,000ProcessMeanCenteredonEachOperationProcessMeanCenteredonEachOperation1101001,00010,000100.0001,000,0001101001,00010,000100.0001,000,000RolledRolled

Yield

YieldNumberofOperationsNumberofOperations1.001.000.900.900.800.800.700.700.600.600.500.500.400.400.300.3000.100.000.00Ast歉heN戏umbe快rof秆Ope谨rati哑ons散Incr栋ease穗s,a佳Hig旱hRoll应edY听ield烧Req扇uire生sa行Highfor窜Each康Ope直rati雾on54366543Pro斜ces顾sM吼ean声Sh遭ift庆ed盛1.5at茅Eac直hO绳per找ati棕on6Over方viewBase乏lini罗ng&肢Ben痕chma论rkin浑gan宣Exi配stin撕gPr琴oces苏sp(并x)Def值ect谣sBen活chm正arkBase我lineEnt主itl来eme找nt

BenchmarkAWorld-ClassPerformance

EntitlementAchievablePerformanceGiventheInvestmentsAlreadyMade

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ReduceCommutetoWorkto15Minutes(withoutworkinganabnormalworkschedule)

TheGoalTheVariables

TimeofDeparturefromHome&RouteTakentoWorkTheApproach

Try3PotentialRoutesatCurrentDepartureTime(7:45),SelecttheBest&VarytheDepartureTime‘tilwegetto15MinutesTime政of偷Depa饺rtur凭e3217:1底57:3桂07:458:008:15Rou柴teCom孙bin免ati盼onSel梨ect丈edThe烈Re春sul稻tUse疼Rout荡e2调andLea急ve简at飘7:1亲5t壮oR共eac寸hG辟oal6Ove火rvi哥ewUsi护ng判“De都sig克no勉fE技xpe搂rim陷ent汇s”洋(DO畏E)Tim律eo霞fD能epa蛇rtu吸reDOE冰(i爱)B错ett笨er大Acc页oun职ts杠for吃In扁ter笔act定ive骨Va敏ria词ble慈sM姿iss岩ed膨by歼“On趣eF谋act危or莲at桨aT富ime屑”,狮and浮(i施i)做Eff种ici师ent议ly击Sea遵rch思es盖for南“S兆wee飞tS邻pot爬”i剩nP爹ara输met怠er缸Spa卷ceThe熊Va秀ria价ble尖sTim妈eo爸fD出epa霸rtu树re企fro衬mHome泰&R说oute摇Tak秘entoW腰orkTheApproach

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ReduceCommutetoWorkto15Minutes(withoutworkinganabnormalworkschedule)

TheGoalAPr什acti光cal玩Exam拦ple(Th看e“愁Coo伏kbo射ok”寒)6Ove微rvi脾ew6怪.and递Baki薪ngB伍readYEAST

FLOURUsin纹ga萍12S聋tep冰Proc粪ess6Ove暂rvi丽ewThe“BETTERBREAD”CompanyStep1Selecting“CriticaltoQuality”(CTQsorY)What厦is步Impo软rtan蚕tto亲the榜Cus劫tome停r?Ris沃eText较ureSmel犯lFres母hnes旨sTast疾eY=T辞ast疼e!!6Ove回rvi伯ewMeas坊ureStep2DefiningPerformanceStandardsforCTQsorY6Over粥viewHow展Coul框dWe狮Mea木sure基Tas投te(柱Y)?Pane博lof陈Tas犯tersRat盒ing螺Sy鹊ste笼mof郑1t据o1封0Targ表et:孩Aver怎ageRat醉ing川at元8Desi怀red:散NoIndi狂vidu接alR休atin畅gs(“de必fect融s”)郊Belo特w7Y=1肢2兼3共4寸5粪67颜8荷9坐10Tar尖getDef躁ect超sWors菠tBestBut.允杏Ist淋his俊the风Righ圈tSy培stem桌?Meas杯ure6Over毅viewStep3ValidatingtheMeasurementSystemforYHow厉Co徒uld晓We旁Ap消pro沃ach识Th辫is?Blin英dfol蚂ded忌Pane哪lRa赴tesSeve茫ral折Loaf巩Sam骂plesPut兼“R茅epe芳at”幕Pi湿ece拆sfrom脚Sam猫eLo享afi免nDiff秃eren获tSa懒mple技sCon授sis湾ten宿tR木ati比ngs穗*o韵nPie屋ces绸fr蚂om勿Sam两eLoa夺f=技“R昏epe镰ata殖bil笔ity卷”Con榜sis抖ten询tR更ati禁ngs仓*o宾nSamp氧les柏Acro秤sst附hePan发el拆=壶“闸Rep服rod柔uci忙bil暖ity双”“Rep近eat旅abi膀lit搏y”悼&“R及epr饶odu妹cib法ili缠ty”伏Su孙gge厌st查Val愿id耳Mea蓝sur万eme抹nt泽App聪roa锅chPane勤lMemb蔽erLoaf殿1Loa帖f2Loa泳f3A589B491C492D898E482F591G892*With浊inOne煤Tast她eUn辽itMeas涂ure6Over扇viewStep4EstablishProductCapabilityforY(Taste)Thi戚si筒sa营3Proc庸ess!7Defe厦cts刃(rat库ing贡sb娇elo响w7)24Rati袍ngs岂(from糟our塘pan生el)=.29零2292,减000Def桂ect蹦sp侵er1,o森oo,裙ooo泡Lo习ave懒sOR765432112345678910#ofRatingsRating64321143Defects<7Target=8Ana酸lyz偏eHow臣DoW威eAp叮proa扯chT垫his?Bake绞Sev桐eral宁Loa幅vesUnd应er垒“No滔rma平l”Cond副itio杜nsHav廊eT续ast励er面Pan皇elAgai虎nDo仓the蓄Rat屯ingAver吩age禽Rati予ngi怠s7.惩4But至Vari饼atio占nistoo炊Grea嫩tfo瞧ra蛇6Pro志ces走s3x10+4x9+6x8+4x7+3x6+2x5+1x4+1x31+1+2+3+4+6+4+36Over病view

Step5DefineImprovementObjectivesforY(Taste)How确do记we声De虹fin爽eI董mpr啄ove亮men孙t?Ben倾chm矛ark逮th神eComp蚁etit挡ionFocu霉son灭Def帐ects(i开.e.疏ta少ste熊ra烦tin蔬g<覆7)Det涌erm北ine余Wh灶atisa必n“A都ccep视tabl菜eSig冤ma语Lev戚el”Set种Im挂pro志vem厚entObj百ect星ive蒸sAcco负rdin妄glyMayb露ea抱5Proc葬ess影Will偏Suf唇fice告!1,00睬0,00德0-100砖,00龄0钻-暂.茄.伶..杏.羊..酷.垄..虽.弄..站.鞋..五.曲..测.玩..题.咬..欠.随..躬.10,0凯00凝-左..搬..捞..全..醒..等..妻..座..喜..腔..隙..线..销..幕..胀.1,00吨0-扔..县..恼..夜..妨..猪..玻..金..弱..新..也..蔑..躁..敬..偿.100钞-丈.说..浙.收..雷.坐..赞.梁..音.闹..贼.型..侮.败..宁.牵..唐.千..耍.罪.10煎-掉..妻..榜..症..烂..让..震..截..毙..染..闲..缘瑞..汽..宜..感.1-2菠3棒4嫂5客6属7“BET蔽TER证BR包EAD丝式”Bak帐ing躲Pr餐oce掠ssBestComp它etit担orRan内ge适forImpr秤ovem遍entDefe妹ctsPer笛Mill村ionSigm籍aSc床ale

Freihofer

WONDER

PepperidgeFarm

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Step6IdentifySourcesofVariationinY(Taste)How奇dow列eDe派term书ine映the院Pote险ntia凳lSo变urce位sof粮Var标iati忧on(凝Xs)?Hav腿et落he贴Che餐fs太Bra挡ins侮tor缘瑞mSome读Lik助ely阳Ones完Mig散htb助e:-A猾moun甩tof余Sal弯tUs帽ed-南Bra芝nd蛇of考Flo拆ur-饱Bak以ing洲Ti吃me-厦Bak认ing蕉Te仅mpe样rat扭ure-女Bra想nd症of纺Yea加stYEAST

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FLOUR

FLOUR

FLOURBrandABrandBBrandCImpr作oveResults:350&BrandAisBestCombinationofTemperature&Flour

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BrandAFlourtobeUsedExceptinCaseofEmergency

“BETTERBREAD”toSearchforBetterAlternativeSupplierofFlourJustinCase

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FLOUR“BrandC”3543533523513503493481级3走5滨7很9脾11胳1县3纱15叉17扇1睬9葱2孟1姿2锄3纪2帽5Cont拨rol9、静夜客四无邻成，荒居刑旧业贫饲。。4月-2陈34月-2姐3Wed怕nes端day犁,A宾pri蠢l2源6,棒202军310、雨中专黄叶树槐，灯下拴白头人绘。。03:5惯3:2703: