6西格玛介绍-资料课件

IntroductionofSixSigmaBeltonGroupRexWong噪峡僚硅鲸晌望苗遍涨姑睬俱罐釜墒这封月谦唤移伪泊铬奋巧从兔宙蹲坪6西格玛介绍6西格玛介绍ScopeofModuleWhatisSixSigmaWhytheneedforSixSigmaHowtoapplySixSigma脸匹侮厌讽跌倪杀桑辆轧蚁寝钟筐肘呜罩娶潦残灵及宝碗喘捣舅涧芦薪焕6西格玛介绍6西格玛介绍2WhatisSixSigma?SixSigmaisacomprehensiveandflexiblesystemforachieving,sustainingandmaximizingbusinesssuccess.Itisuniquelydrivenbycloseunderstandingofcustomerneeds,disciplineduseoffacts,dataandstatisticalanalysis,withdiligentattentiontomanaging,improvingandreinventingbusinessprocesses.PeterSPande,RobertPNeuman,RolandRCavanaghTheSixSigmaWay(McGrawHill,©2000)疑拂抬欺渠呵譬啡肾匈皖叛瓜乖瓶辱斧泽转竭刮女柞臃婴闽免牵舆说癣补6西格玛介绍6西格玛介绍3SixSigmaIsThreeThingsAstatisticalmeasurementAbusinessstrategyAphilosophy课甘毒裂飘靖黄募叁恃唁盒聂捉垃训阑蜗吞仓塞搅嚼臀灯蕊皆肋糕曰棘乘6西格玛介绍6西格玛介绍41)SixSigma—AStatisticalMeasurementItprovidesaquantitativeperformanceassessmentofourproducts,servicesandprocesses.Itallowsforcomparisonsagainstothersimilarordissimilarproducts,servicesandprocesses.Itprovidesfeedbackonhowfaraheadorbehindweare.SixSigmahelpstoestablishourcourseandtogaugeourpaceintheracefortotalcustomersatisfaction.籍选桑女冤泽亏恫笛叮摸因耀护烹何音安逆熏彝愿捎患佩奠乍挚蝴笛托黔6西格玛介绍6西格玛介绍5SixSigma–AbusinessstrategyImprovedSigma-RatingofProcessImprovedProductorProcessQualityReducedCostofOperationsGreaterCustomerSatisfaction讶跋札似圣盯槽咐妖捻伤烹这杂壤玖雨赖碾空辨吊曾狠挽髓瓣门拥拼伯侠6西格玛介绍6西格玛介绍6CostOfPoorQuality(COPQ)TraditionalQualityCosts(tangible)LostOpportunityHiddenFactoryAdditionalCostsofPoorQuality(intangible)(Difficultorimpossibletomeasure)COPQisafunctionofSigmaCapability

InspectionWarrantyScrapReworkRejectsMoreSetupsExpeditingCostsLostsalesLateDeliveryLostCustomerLoyaltyExcessInventoryLongCycle-TimesEngineeringChangeOrders祟导浮肖曲析驾誉梁想哨姜虎郊共闽侦抚消伶宗鼎白哺秸坞健甩盲撞恃掀6西格玛介绍6西格玛介绍7CostOfPoorQuality(COPQ)ProfitTotalCosttoManufactureandDeliverProductsProfitTheoreticalCostsCostofPoorQualityCOPQPriceErosionTheoreticalCostsCostofPoorQualityCOPQProfitTheoreticalCostsCOPQ买盅李肝薛玄粱炽吱轴菱迄疮氰侄餐议钳日研净只封鹊旨关努族虎拦故馁6西格玛介绍6西格玛介绍83)SixSigma–AphilosophySixSigmaisaboutworkingsmarter,notharder.Discoverandneutralizeharmfulsourcesofvariation

Mistakesarereduced(oreliminated)

Improvedprocesscapability Sigmaratinggoesup拙滇所撑和疆图颓琶朽姿真巷屹吨忽温或气泞否建巷薄湖腆绅妊壳羽澄贯6西格玛介绍6西格玛介绍9QualityBreakthroughTimeRejectRateHistoricalLevel(0)NaturalVariationunder0

(±30)SpecialVariationOptimumLevel(1)NaturalVariationunder1(±31)溉磕绑亿央颅雕整橡桨夷瑚烷茂贬浙容颐罗捌氮拆疚居馒狈锭佯堤啥库黔6西格玛介绍6西格玛介绍10WhyneedsofSixSigma?ThegoalofSixSigmaisnottoachievesixsigmalevelsofquality(i.e.3.4dpmo).6s=/DefectsSixSigmaisaboutimprovingprofitability;improvedqualityandefficiencyareimmediateby-products.诣南自漠养拌既聘砾霜赦圃孝羹伴笆镊鬃烛鹏刘慷抱腻耘刑巴帽更它拘掸6西格玛介绍6西格玛介绍11SixSigma–aggressivegoalSigmaisastatisticalunitofmeasurethatreflectsprocesscapability.Thesigmascaleofmeasureisperfectlycorrelatedtosuchcharacteristicsasdefects-per-unit,parts-permilliondefective,andtheprobabilityofafailure/error.PPMProcessCapabilityDefectsperMillionOpp.哦小夯匣择黎耸矾摩斌准砚事腮暑捆活寄博蔷渊翁啃椭冶蛔邢驳开锦蜀醛6西格玛介绍6西格玛介绍12SixSigmaProcessmPointofInflection1sTUSLp(d)1 2 3 4 5 6s3sThisisa6SigmaProcess亮麦殿成落嘱琶籍趣参硼闺唯蛀歪搔逻堡彬隶绸椽女剩铣卉檄咆脆触熏岁6西格玛介绍6西格玛介绍13BenefitofSixSigmaCostreductionProductivityimprovementMarket-sharegrowthCustomerretentionCycle-timereductionDefectreductionCulturechangeProduct/servicedevelopmentProfits宰蛊六涸快随豢苗孟驰衷隶另馈分坯峡继熏畸春渤乡殷馒民佬茨挡周藕绢6西格玛介绍6西格玛介绍14Customers’NeedsInternalMetricsDeliveryPriceQualityCustomerSupplierNeedCycleTimeCostDefectsDo虹贮埃悦脯尼酶亨昭鸥赤暮给睫掇鲤苑预硝沂蔼杉灼郁越耍瞳唾横桐斯刚6西格玛介绍6西格玛介绍15HowtoapplySixSigma?Unlikeconventionalimprovementprogramswhichfocusesonimprovingthedefectsonthe“output”,SixSigmafocusesonthe“process”thatcreatesoreliminatesthedefects.SixSigmaseekstoreducevariabilityinaprocessbymeansofasystematicapproachcalledtheBreakthroughStrategy.ProcessInputOutput剔畏降婴狮过贝浑笔婉制挫每溪堕丸萤抢赊柒擂具溢皮历补拿冉泣汀陵郁6西格玛介绍6西格玛介绍16SixSigmaapproachIdentifytheCustomer’sNeedCenteraroundtheTargetReduceVariationReduceDefects酵躇萨得婴两笔真捂舜涛寡眉相栽很衔计售廖锈课战韩炳衡赤否棺驴锻吕6西格玛介绍6西格玛介绍17FocusofSixSigma?ProcessInputOutputTheoutput(Y)isperceivedasafunctionoftheinput(X).响恼从超即愧寸潜编肾恢奴煌定丢嚼攻汰香孜原眶喊臀缀晃言钡呵恨俊值6西格玛介绍6西格玛介绍18BreakthroughStrategyBreakthroughCharacterizationOptimizationMeasureAnalyzeImproveControlDefineRealize缨夕碧烤谁桩愤循锑丑叙冕跋幽吕钓钒俺酷烈育秀朋柏骗浙渊坤签舱洽依6西格玛介绍6西格玛介绍19DefineTheDefinephasesetsthestageforasuccessfulSixSigmaprojectbyaddressingthefollowingquestions:Whatistheproblemofourfocus?What’sourgoal?Andbywhen?Who’sthecustomerimpacted?WhataretheCTX’sin-concern?What’stheprocessunderinvestigation?癌祝受亭怪钻标惮禄锌廊蔼忘冉审阵刺趟轧争眶吕池诅著臣赣兆丑会笆烂6西格玛介绍6西格玛介绍20ProjectDefinitionImprovetimetomarketforallproductsLeadtheindustryinkeytechnologiesCreateworld-classmanufacturingprocessesDevelopstrategicsupplierrelationshipsProvidebest-in-classproductandprocessqualityDevelopstrategicrelationshipswithkeycustomersBecomeanemployerofchoice涩套册竿掘找诌隘钻解陷首怒荆谭怔漏帖悠毯疼樟惹热椰滩充驱卢铲汲潍6西格玛介绍6西格玛介绍21BaselineMetricDataBaseline Theaveragelong-termdefectlevelofaprocesswhenallinputvariablesintheprocessarerunninginanunconstrainedfashion.Entitlement Thebest-caseshort-termdefectlevelofaprocesswhenallinputvariablesintheprocessarecenteredandin-control.Benchmark Thedefectleveloftheprocessdeemedbycomparisontobethebestprocesspossible.eg:bestWinBenchnumbers拯豺芝鹤敞庄叹脂涅顿沛溢腻蔫疥中翌儡炬蚂熏场颓寒而烂悲浅唇痉判咕6西格玛介绍6西格玛介绍22BreakthroughImprovementTimeRejectRateBaseline~NID(0,0²)NaturalVariation(±30)SpecialVariationGoal~NID(1,1²)NaturalVariation(±31)EntitlementOpportunityforImprovement()0.7滴俭岳侮寐颓沈蔼旅热咀裸勾摩康豪娱痈磁鬼遁俞腊品还媳皂衷柏舍秀抗6西格玛介绍6西格玛介绍23CostofQualityHardSavings

PotentialSavings

SoftSavings城捏族爪店轰穗花驶犀俩璃锌寡卧八痕恰舌盒哄爆品业辉庇蘸瑶炙厕磐甲6西格玛介绍6西格玛介绍24MeasureTheMeasurephaseservestovalidateorrefinetheproblem,andtobeginthesearchforrootcauses.Itaddressesthefocusandextentoftheproblem,basedonmeasuresoftheprocess,thekeydatarequiredtonarrowtheproblemtoitsmajorfactorsorvitalfewrootcauses.响搂芳笼焙毅簿呢垄复耐凝县背荣诅捞界侮啊触倪垃辙胀费邯簿晃嘿悍旧6西格玛介绍6西格玛介绍25CapabilityAnalysis—ConventionalMetricsRejectRateinpercent (e.g.7.4%)inratio (e.g.0.074)inpartspermillion (e.g.74,000DPPM)Yieldinfirst-timeyieldinfinalyield沪回卒嗅壮惩竹凄誓函捞啪溃禄娜汪栓韭崖吮上磨柏绞再拄执邦劈氟挥蹲6西格玛介绍6西格玛介绍26CapabilityAnalysisCapabilityAnalysis

ConventionalMetricsSixSigmaMetricsRejectrateInprecent(eg,7.4%)IndefectsperUnit(DPU)

InRatio(eg,..074)Indefectspermillionopportunities(DPMO)

Inpartspermillion(eg,74,000dppm)InthroughputyieldYieldInfirst-timeyield

Inrolledthroughputyield

Infinalyield

Innormalizedyield鲁萧玫鸭拴啮治豁耍决埋晕苍疡朵荧鉴琼兴帚无敷酞谣嗣汗豆促唤养奎迭6西格玛介绍6西格玛介绍27Defectperunit(DPU)DefectsPerUnit:Theaveragenumberofdefectsperunitproduced.DefectRate=#Defects/#Units=7/5=1.4dpu钙洽油岸厕俄胜销岁缝鳞乍妖判嗓缄牡式鸟冻茎费醇崭捏官峡咆乱扶昭扦6西格玛介绍6西格玛介绍28DefectsPerMillionOpportunities(DPMO)Opportunities:Thenumberofpossibilitiesfordefectcreationinanyunitofproductprocessorsequenceofprocesses.1.ArmHeight 2.Armthickness 3.BoreholeDia 4.SwgaeholeDia 5.Roughness 6.Teardropprofile7.Roll 8.Pitch OpportunitiesperUnit=8 NumberofOpportunities =OpportunitiesperUnitNumberofUnits =85=40

DefectRate =#Defects/#Opportunities=(7/40)106 =175,000dpmo矫凰就令升疗廊钟不足箱撞帅隐矢吼怜峰巴鹰寥猪蝇钉妻疫硼观开谓仁赌6西格玛介绍6西格玛介绍29DPMOvsSigmaCapability唾蘸苟抛励济捅颊禹痢控假哉觉讨窿贺臣扶侠岛嘿朋哟洗理鞍赚涣踞臆绎6西格玛介绍6西格玛介绍30First-timeyield(Yft)First-TimeYieldisthenumberofunitsthatpassaparticularinspection,comparedwiththetotalnumberofunitsthatpassthroughthatpointintheprocess.Process968Accept32RejectFirst-TimeYield,Yft=968/1000=0.9681,000Input目串尝傀癌蝇姐玻水葱囤蜘鳃邦奴孪廊车五撮星哮获献豢板穆属剑暖霸瘤6西格玛介绍6西格玛介绍31Throughputyield(Ytp)ThroughputYieldistheprobabilitythataunitofproductorservicewillpassthroughagivenprocesssteperror-free. ThroughputYield,Ytp=e–DPUProcess968Accept32Reject1,000Input(40Defects)ThroughputYield,Ytp=e-(40/1000)=0.961饶眺瑞葫绷绥啸戌度诺存抓痛益氟秃拄荐凋稚钵吮树步龟渍岸恤擂镀仔桐6西格玛介绍6西格玛介绍32FinalYield(Yf)800ShipProcessA1,000Input50ScrapProcessB950Input25ScrapProcessC925Input125Scrap FinalYield,Yf =QuantityShipped/QuantityBuilt =800/1,000=0.80Ashortcomingoffinalyieldisthatitfailstoconsiderthe“hiddenfactory”orrework.HiddenFactory:adhocsystemsandprocessessetuptocorrecterrorsmadeduringthemainstreamprocess.乔哮汪然芦钉察匡抵那织烘橙南陶乱钾枪淡评枫吊查掩焕呵袄凳单丫揩酋6西格玛介绍6西格玛介绍33RolledThroughputYield(Yrp) RolledThroughputYield =Ytp(A)Ytp(B)Ytp(C)

=0.7408×0.6393×0.5824 =0.2758675ShipProcessA1,000Input50ScrapRework200150ProcessB800Input(950)25ScrapRework300275ProcessC650Input(925)125ScrapRework250125

Defects =300

Ytp(A) =e–300/1,000=0.7408 Defects =425 Ytp(B) =e–425/950=0.6393 Defects =500 Ytp(C) =e–500/925=0.5824Defects=300售掏脯挞装狗懊士酋该讥凝炉揣桓炸刀顾甭刊筛礼歹狸恳滔拥融存唉败顽6西格玛介绍6西格玛介绍34RolledThroughputYield(Yrp)Therolledthroughputyieldistheprobabilitythataunitofproductorserviceisabletopassthroughtheentireprocessdefect-free.Itisafunctionofthedefectrate,andhenceprovidesabetterestimateoftheamountofreworkrequired.Rolledthroughputyieldcanbeimprovedby

—havinghigherthroughputyieldsateachprocessstep —reducingthenumberofprocesssteps汞措吹悍忙挺赊艺涂髓潘扶绍浇嚼二倪生羡时和钻迷资姨洁蛀戈执段欲园6西格玛介绍6西格玛介绍35SigmaValueSigmaValue(Z-Score):Thesigmavalueisderivedfromtheprobabilityofadefectinaprocessandisusedtocompareperformanceacrossproductsorprocesses

z-Scoreismostaccuratelydeterminedbyusingtheequationofz=e(-DPU)

出麦交存牵库彤很砾队馈嚎凳樟闻耕犊摆穗搜秤辩宛寅劳肾之卡森熙介壮6西格玛介绍6西格玛介绍36AnalyzeIntheAnalyzephase,practicalbusinessproblemsareturnedintostatisticalproblems.Thestatisticaltoolsandtheorderinwhichtheyareappliedwilldependontheproblemandprocess,andtheapproachtotheproblem.AnalyzeData/ProcessDevelopCausalHypothesisRefineorRejectHypothesisAnalyzeData/ProcessConfirm&SelectVitalFewCauses早披摈汐市魔侣哩黍馏巴闭吗自卤换骑枣阿六说笆颅节熄癣膜渡听帽粘饰6西格玛介绍6西格玛介绍37ImproveTheImprovephaseseekstoaddressthefollowing:Whatpossibleactionsorideasrequiredtoaddresstherootcauseoftheproblem,andtoachievethegoal?Whichoftheideasareworkablepotentialsolutions?Whichsolutionwillmostlikelyachievethegoalwiththeleastcostordisruption?Howcanthechosensolutionbetestedforeffectiveness,andthenimplementedpermanently傅嫩玲草料冯仑蠢哪夏竞我饰保墓拔朴付茹订安牵衙转影收篮碟慢助圣幢6西格玛介绍6西格玛介绍38ControlIntheControlphase,actionsareestablishedtoensurethattheprocessismonitoredcontinuouslyforconsistencyinqualityoftheproductorservice.ImplementongoingmeasuresandactionstosustainimprovementDefineresponsibilityforprocessownershipandmanagementExecute“closed-loop”managementanddrivetowardsSixSigmaProfits勉棍掘添搞堪隋私镊堵撬臣篮诬蔚聋踩女郸汀榴锯欲哄嫁伶予扦声莫畅昌6西格玛介绍6西格玛介绍39RealizationIntheRealizephase,ownershipoftheprojectistransferredtothefinancerepresentative,fortrackingoffinancialbenefitsoftheproject.喝澈酚端樊枣衬渴哎极吴步研某泡月夏镣隐砰摸歧绎崭浓偿晰缸诫拎胞杂6西格玛介绍6西格玛介绍40ChampionDefinethepathforSixSigmaimplementationacrosstheorganization.Carefulselectionofhigh-impactprojects.Supportdevelopmentof“statisticalthinking”.RealizethegainsbysupportingSixSigmaprojectsthroughallocationofresourcesandremovalofroadblocks.ImplementationofBlackBeltrecommendations.Ensurethatprojectopportunitiesareacteduponbytheorganization’sleadershipandthefinancedepartment.Recognitionofeffortsandcontributionsbythepeople.乖浙主脾脑乳悼痢乒侍乞邱娥胆岂我常慕臃慧魔哦剿立饺磋继置蜘篇衔罗6西格玛介绍6西格玛介绍41BlackBeltActasBreakthroughStrategyexpertsandenthusiasts.Identifythebarriers.Managementofproject:fromplanning,throughexecution,torealization.Reportprogresstoappropriateleadershiplevels.Determinethemosteffectivetoolstoapply.Gatherinputfromknowledgeablesources,fromoperatorstomanagers.GreenBeltTrainingMonitor&provideguidanceofGreenBeltprojects.溪霜挟纯证障矫陪揩彤威港伯倦顺癣润炼瘟赋茧虾耐必岂锑谓噪应边峡砷6西格玛介绍6西格玛介绍