6S 标准培训教材ppt.ppt

AnOverview.NotalotofDetails!,6Overview,“SixSigma”,Ifwecantexpresswhatweknowintheformofnumbers,wereallydontknowmuchaboutit.Ifwedontknowmuchaboutit,wecantcontrolit.Ifwecantcontrolit,weareatthemercyofchance.,MikelJ.HarryPresidentTakingGEFroma3toa6CompanyWillSave$10.5BillionperYear!,Why“SixSigma”?,ProvenSuccessfulin“Quality-Demanding”Industriese.g.,Motorola,TexasInstruments(manyprocessstepsinseries)ProvenMethodtoReduceCostsHighlyQuantitativeMethodScienceandLogicInsteadofGutFeelIncludesManufacturing&Service(closetocustomer)andProvidesBridgetoDesignforQualityConceptsHasSupportandCommitmentofTopManagement,ItWorks!,6Overview,6isSeveralOrdersofMagnitudeBetterThan3!,Sigma:AMeasureofQuality,6Overview,WhereDoes“SixSigma”ComeFrom?,MikelJ.HarryoneoftheOriginalArchitectsPreviouslyHeadedQualityFunctionatABBandMotorolaNowPresident/CEOofSixSigmaAcademyinPhoenix,ArizonaHasConsultedforTexasInstruments,AlliedSignal(andothers)CurrentlyRetainedbyGEtoTeachtheImplementation,DeploymentandApplicationofSixSigmaConcepts&Tools,LearningfromThoseWhoHavehadSuccessWith6WillAccelerateitsImplementationatGE,6Overview,So.WhatisSixSigma?,“THESIXSIGMABREAKTHROUGHSTRATEGY”,6Overview,HowDoWeArriveatSigma?,Measuring&EliminatingDefectsisthe“Core”ofSixSigma,MeasurementSystem,IdentifytheCTQs,LookforDefectsinProductsorServices,“CriticaltoQuality”CharacteristicsortheCustomerRequirementsforaProductorService,CountDefectsorfailurestomeetCTQrequirementsinallprocesssteps,DefineDefectOpportunities,AnystepintheprocesswhereaDefectcouldoccurinaCTQ,ArriveatDPMO,UsetheSIGMATABLE,ConvertDPMOtoSigma,DefectsPerMillionOpportunities,23456,308,53766,8076,2102333.4,PPM,DefectsperMillionofOpportunity,SigmaLevel,6Overview,MeasurementSystem,23456,308,53766,8076,2102333.4,PPM,SIGMALEVEL,DEFECTSperMILLIONOPPORTUNITY,IRSTaxAdvice,BestCompanies,AirlineSafety,AverageCompany,GE,AverageCompanyin3to4Range,SomeSigma“Benchmarks”,6Overview,MeasurementSystem,AGraphic/QuantitativePerspectiveonVariation,AverageValue,ManyDataSetsHaveaNormalorBellShape,NumberofPeopleArrivingatCRD,Time,7:00,7:15,7:30,7:45,8:00,8:15,8:30,8:45,9:00,9:15,6Overview,ProblemSolvingApproach,6HelpsusIdentifyandReduceVARIATIONdueto:-InsufficientProcessCapability-UnstableParts&Materials-InadequateDesignMargin,Target,USL,LSL,Target,USL,LSL,Target,USL,LSL,CenterProcess,ReduceSpread,Off-Target,Unpredictable,On-Target,6Overview,ProblemSolvingApproach,“LowerSpecificationLimit”,“UpperSpecificationLimit”,LessVariationMeansFewerDefects&HigherProcessYields,6Overview,ProblemSolvingApproach,KeyComponentsof“BREAKTHROUGHSTRATEGY”,IdentifyCTQ&CTP(CriticaltoProcess)VariablesDoProcessMappingDevelopandValidateMeasurementSystems,BenchmarkandBaselineProcessesCalculateYieldandSigmaTargetOpportunitiesandEstablishImprovementGoalsUseofParetoChart&FishboneDiagrams,UseDesignofExperimentsIsolatethe“VitalFew”fromthe“TrivialMany”SourcesofVariationTestforImprovementinCenteringUseofBrainstormingandActionWorkouts,SetupControlMechanismsMonitorProcessVariationMaintain“InControl”ProcessesUseofControlChartsandProcedures,AMixofConceptsandTools,WillAlsoIntegratewithNPIProcess,6Overview,DisciplinedChangeProcess,ANewSetofQUALITYMEASURES,CustomerSatisfactionCostofPoorQualitySupplierQualityInternalPerformanceDesignforManufacturability,WillApplytoManufacturing&Non-ManufacturingProcessesandbeTracked&ReportedbyEachBusiness,6Overview,Structure,6ProjectswiththeGEBusinesses,TabulationofGESixSigmaResults,BenefitTarget&Update,Currentbenefitslevel10.865MM,QPIDloading:Carryoverfrom1999:4.059CompletedProjects2000:3.313ActiveProjects2000:3.285Total:10.865MM,KeyConcepts&Tools,6Overview,6Overview,ChangingFocusFromOutputtoProcess,IdentifyingandFixingRootCausesWillHelpusObtaintheDesiredOutput,f(X),Y=,ProcessCapability,6Overview,SustainedCapabilityoftheProcess(longterm),USL,T,InherentCapabilityoftheProcess(shortterm),LSL,Target,OverTime,a“Typical”ProcessWillShiftandDriftbyApproximately1.5,6Overview,“ShortTermCentered”versus“LongTermShifted”,SixSigmaCentered,LSL,T,ProcessCapability,.001ppm,.001ppm,+6,LSL,USL,T,3.4ppm,SixSigmaShifted1.5,ProcessCapability,HigherDefectYieldinLongTermProcessCapabilitythanShortTermProcessCapability,-6,6Overview,TyingitAllTogether,shift,C,D,A,B,0.51.01.52.02.5,123456,CONTROL,POOR,GOOD,TECHNOLOGY,POOR,GOOD,shortterm,ProblemCouldbeControl,TechnologyorBoth,6Overview,ShortTermCapability,ShortTermCapabilityRatio,(Cp),Cp=,LSL,-,6,USL,Example,6,3.0,-,(-3.0,Cp=,Cp=,1,LSL,USL,2.5,0.5,3.0,ProcessMean,T,Target,A3Process,ThePotentialPerformanceofaProcess,ifitWereonTarget,6Overview,LongTermCapability(Cpk),LongTermCapabilityRatio,Example,Cp=,1(previouschart),Target,=,-0.5,=,0,Cpk,1-,(-0.5,-,0,3,=,Cpk,=,0.83,-,Off-TargetPenalty,ThePotentialPerformanceofaProcess,CorrectedforanOff-TargetMean,LSL,USL,2.5,0.5,3.0,ProcessMean,T,Target,A3Process,6Overview,Z-ScaleofMeasure,Z,=,AUnitofMeasureEquivalenttotheNumberofStandardDeviationsthataValueisAwayfromtheTargetValue,-3.0,-0.5,3.0,Z-Values,USL,LSL,2.5,0.5,3.0,=ProcessMean,Z,T,Target,0,A3Process,TheDefinitionsofYield,FirstTimeYield(Yft),=,UnitsPassed,UnitsTested,=,65,70,=,0.93,RolledThruputYield(Yrt),=,(Yield1),(Yield2),(Yield3).,=,91,82,65,70,(,(,(,(,),),),),=,0.65,100,91,70,82,NormalizedYield(Ynm),=,=,1/n,(Yrt),(0.65),1/4,=,0.89,(n:TotalNumberofProcesses),6Overview,YieldExclusiveofRework,ProbabilityofZeroDefects,AverageYieldofAllProcesses,6Overview,AstheNumberofOperationsIncreases,aHighRolledYieldRequiresaHighforEachOperation,5,4,3,6,ProcessMeanShifted1.5atEachOperation,6Overview,Baselining&BenchmarkinganExistingProcess,p(x),Defects,Benchmark,Baseline,Entitlement,Baselining=CurrentProcess/Benchmarking=UltimateGoal,SomeBasic6-RelatedTools,6Overview,ScatterDiagram,OverSlept,CarWouldNotStart,Weather,FamilyProblems,Other,ParetoDiagram,FrequencyofOccurence,ReasonsforBeingLateforWork,ArrivalTimeatWork,TimeAlarmWentOff,Materials,People,TheHistogram,6Overview,SomeBasic6-RelatedTools,PlotofDailyArrivalTime,9:15,7:00,7:15,7:30,7:45,8:00,8:15,8:30,8:45,9:00,AverageValue,NumberofPeopleArrivingatCRD,Time,6Overview,LCL,UCL,RangeChart,SomeBasic6-RelatedTools,MonitorsChangesinAverageorVariationOverTime,DesignofExperiments,6Overview,SCREENING,OPTIMIZATION,CHARACTERIZATION,ForExperimentsInvolvingaLargeNumberofFactorsUsefulinIsolatingthe“VitalFew“fromthe“TrivialMany”,ForExperimentsInvolvingaRelativelySmallNumberofFactorsUsefulWhenStudyingRelativelyUncomplicatedEffects&Interactions,ForExperimentsInvolvingOnly2or3FactorsUsefulWhenStudyingHighlyComplicatedEffects&Relationships,DOEisMoreEffectiveThanTestingOneFactorataTime,6Overview,Usingthe“OneFactorataTime”Approach,TimeofDeparture,321,7:15,7:30,7:45,8:00,8:15,Route,CombinationSelected,TheResult,UseRoute2andLeaveat7:15toReachGoal,6Overview,Using“DesignofExperiments”(DOE),TimeofDeparture,DOE(i)BetterAccountsforInteractiveVariablesMissedby“OneFactorataTime”,and(ii)EfficientlySearchesfor“SweetSpot”inParameterSpace,TheVariables,TimeofDeparturefromHome&RouteTakentoWork,TheResult,ABetterCombinationAllowing15MoreMinutesofSleep!,ActualCommutingTimeAverages(minutes),321,7:15,7:30,7:45,8:00,8:15,Route,1720232119,1518201916,1215212018,OriginalConclusion,BestCombination“SweetSpot”,APracticalExample(The“Cookbook”),6Overview,6.andBakingBread,Usinga12StepProcess,6Overview,WhatisImportanttotheCustomer?RiseTextureSmellFreshnessTaste,Y=Taste!,6Overview,Measure,6Overview,HowCouldWeMeasureTaste(Y)?PanelofTastersRatingSystemof1to10Target:AverageRatingat8Desired:NoIndividualRatings(“defects”)Below7,Y=12345678910,Target,Defects,Worst,Best,But.IsthistheRightSystem?,Measure,6Overview,HowCouldWeApproachThis?BlindfoldedPanelRatesSeveralLoafSamplesPut“Repeat”PiecesfromSameLoafinDifferentSamplesConsistentRatings*onPiecesfromSameLoaf=“Repeatability”ConsistentRatings*onSamplesAcrossthePanel=“Reproducibility”,“Repeatability”&“Reproducibility”SuggestValidMeasurementApproach,PanelMember,Loaf1Loaf2Loaf3,A589B491C492D898E482F591G892,*Within,OneTasteUnit,Measure,6Overview,Thisisa3Process!,7Defects(ratingsbelow7),24Ratings(fromourpanel),=,.292,292,000Defectsper1,ooo,oooLoaves,OR,Analyze,HowDoWeApproachThis?BakeSeveralLoavesUnder“Normal”ConditionsHaveTasterPanelAgainDotheRatingAverageRatingis7.4ButVariationistooGreatfora6Process,6Overview,HowdoweDefineImprovement?BenchmarktheCompetitionFocusonDefects(i.e.tasterating7)DetermineWhatisan“AcceptableSigmaLevel”SetImprovementObjectivesAccordingly,Maybea5ProcessWillSuffice!,1,000,000-100,000-.10,000-.1,000-.100-.10-.1-,234567,“BETTERBREAD”BakingProcess,BestCompetitor,RangeforImprovement,DefectsPerMillion,SigmaScale,Analyze,6Overview,HowdoweDeterminethePotentialSourcesofVariation(Xs)?HavetheChefsBrainstormSomeLikelyOnesMightbe:-AmountofSaltUsed-BrandofFlour-BakingTime-BakingTemperature-BrandofYeast,MultipleSources:Chefs,Suppliers,Controls,Analyze,6Overview,HowdoweScreenforCausesofVariation(Xs)?DesignanExperimentUseDifferentSourcesofPotentialVariationHavePanelRatetheBreadUsedintheExperimentResultsLeadtothe“VitalFew”Causes,Source,Conclusion,Negligible,MajorCause,Negligible,MajorCause,Negligible,FocusonThe“VitalFew”,Improve,