6σ_concept_understanding.ppt

Understanding6 SixSigma LGElectronics PCDivisionQATeam LGEInternalOnly Contents Whatis6 activity 1 Whatarethestatistics 2 SolutionofthePracticalProblem3 Whatisthe6 concept 4 6 Application5 6 ActivityProcess6 Comparewithothertools7 6 Philosophy Whyshouldwedo6 Quality FailureRate HowtoLaunch6 KeyFactorforSuccessof6 WhatisRolledThroughputYield 1 Whatarethestatistics Population Sample Sample PopulationN 1 000 Measure10samples Spec 100 4 Youmaysay ThisPopulationisGoodbecauseallthesample sdataarelocatedbetweenLSL USL BUT Ifyouestimatethedefectrateusingstatisticalanalysis thispopulationhastheprobabilityof2 8 defectsperunit Thenthisis wecall Anepidemic qualitydefectlevel Measuringdefectrateonprocessthroughanexpandingstatisticalconcept wecanusemeasuringprocesscapability Whatis6 activity 96 97 98 99 100 104 101 102 103 Totalinspectionisimpossible Statisticalvariables mean variance estimatepopulation USL USL T USL USL T USL USL T PrecisebutnotAccurate AccuratebutnotPrecise ShiftingtoTarget ReducingVariation ShifttoTarget ReducingVariation 2 SolutionofthePracticalProblem Whatis6 activity Objectof6 is ShifttoTarget ReducingVariation 6 QualitymeansthatareaoftheestimatednormaldistributionislocatedbetweenUSL LSLwith 6 Inthatcaseareaoftheoutlierspec Inotherwordsestimateddefects isjust3 4PPM StandardDeviationStatisticindexmeasureshowmuchdataapartfromtargetvalue 3 4ppm Target USL LSL 6 6 3 3 6 68 3 Whatisthe6 concept Whatis6 activity StatisticalDefinitionof6 3 6 63 4523346 210366 8072308 537 PPM 1misspelledwordinallofthebookscontainedinasmalllibrary 340indebtednessper 100millionsassets1 8minutesperyear 1 5misspelledwordsperpageinabook 6 7millionsindebtednessper 100millionsassets24daysperyear Whatis6 activity 6 astheBusinessStrategy 3 Whatisthe6 concept InallDesign Manufacturing andSVCprocessesApplyingfor6 statisticTools ProcessesTofindfactorscausingdefectsActingtheAnalysisandImprovementThroughtheDefectReduction IncreaseYield TotalCustomerSatisfactionManagementInnovationToolcontributestoManagementOutput Achieving3 4PPM 3 4DefectsPerMillion Whatis6 activity PPM PartsperMillion Whatis6 activity 6 astheActivity 3 whatisthe6 concept 4 6 Application SelectingCTQtomeetcustomerneedsDecisionreasonableToleranceGuaranteeoftheCTQ scapabilityanalysis ImprovementseriousproblemusingS WRealTimeMonitoringsystem CTQControlsystem ImprovementcycletimeandaccuracyCostImprovement GuaranteefortheDesigncompletionindevelopingstage Qualityassuranceinmanufacturingstage Maximizingforsales SVC 6 isatoolthatappliestoallbusinesssystems Design Manufacturing SalesandSVC Whatis6 activity R D6 Manufacturing6 De sign Sales SVC Mfg 6 Transaction6 Design Mfg Sales SVC IdentifyCustomer DrivenCTQ CriticaltoQuality Characteristics IdentifyKeyProcessesthatcauseDefectsinaCTQCharacteristics ForEachProductorProcessCTQ Measure Analyze Improve Control 6 isarigorousanalyticalprocessforsolvingproblem 5 6 ActivityProcess Whatis6 activity 1 Whoareyourcustomers Internal External2 Whatdoyouprovideyourcustomers 3 Whatiscriticaltoqualityforyourcustomers 1 WhatareyourinternalprocessesforprovidingyourproductorserviceCTQ stoyourcustomers 2 Wheredodefectsoccurintheseprocesses D PracticalProblemMeasurementSystemYieldCalculation ProcessMapping Calculation BenchmarkingParetoChart Stratification Cause EffectDiagram DOEBrainstorming ActionWorkoutTechniquesPiloting ControlMechanismControlChart Procedures M A I C 6 ActivityProcess manufacturing Transaction CTQ CriticalToQuality Yourcustomersfeelthatcharacteristicofproduct serviceorprocessiscritical D Define ExampleofdevelopmentprocessappliedbyR D6 R D6 Kick Off Evaluationmeetingforpresentcondition Evaluationmeetingforbasicconcept Evaluationmeetingforplanningconfirm E Sdrawingconfirm Custo merNeedsSurvey QFDS 1 SpareCTQSelec tion SimilarprocessDatagathering ZValueofCTQAnalysis MeetingforCTQCheck ZValueoptimize Designimprove QFDS 2 DesignFMEA ProcessFMEA DevelopmentProcess E Smaking Developmentdrawingconfirm IncomeParts E SQualitymeeting P LMaking P LQualityMeeting Incomeparts P PMaking P PQualitymeeting CTQDatafornewpartsgathering Activityforprocessimprove ment CTQfornewpartsConfirm CTQdeci sion ZValueofCTQconfirm 5 6 ActivityProcess Whatis6 activity Define Measurement VarianceofCTQ Presentcon ditionAnalysis Improvedbyexpert sIdea Controledbycontrolchart Process4Mcontrol Measure Symptoms Frequency Analysisforstatistics Effectanalysiscausedfactors Optimizingconditionbystatisticalanalysis Others 6 DiscreteData Difficulttoapplypracticalproblembecauseofcomplexity Discrete Continuousdata Easytoapplybecauseofsupportingstatisticalsoftware Analysis Improvement Control ControledbyPTS CTQ Benefits Focusingexperience technology PTS ProjectTrackingSystem ByImprovementProcess Whatis6 activity 6 Comparewithothertools 6 Comparewithothertools Detectingprocessdefects Productmanagingcomparewithspec Judgingeachperson sKnow How ManualDatagathering analysis Controlprocessvariation JudgingthestatisticData Simple EffectiveanalysisusingtheS W PreventionControlvitalfewfactors ManagingTool ImprovementTool SelectingLine DoprocessFMEA SelectingCostissueprocessviewofcustomer ConformCTQprocess Sortingtheprocess Justneedcontrolprocess Importantcontrolprocess Lawapplicationprocess Variationimprovement 100ppm 6 applicationaccordingtosortingprocess 100ppm 6 Whatis6 activity 100ppm 6 100ppm 6 Application Wedon tknowwhatwedon tknow Ifwecan texpresswhatweknowintheformofnumbers wereallydon tknowmuchaboutit Ifwedon tknowmuchaboutit wecan tcontrolit Ifwecan tcontrolit weareatthemercyofchance 7 6 Philosophy Whatis6 activity Oursurvivalisdependentupongrowingthebusiness Ourbusinessgrowthislargelydeterminedbycustomersatisfaction Customersatisfactionisgovernedbyquality price anddelivery Quality price anddeliveryarecontrolledbyprocesscapability OurProcesscapabilityisgreatlylimitedbyvariation Processvariationleadstoanincreaseindefects cost andcycletime Toeliminatevariation wemustapplytherightknowledge Inordertoapplytherightknowledge wemustfirstmeasureit Measuretheproblem we llgettherightknowledge Whatis6 activity 7 6 Philosophy GenerallycontrolledF CosthassmallportionconsideringofHiddenLoss TraditionalF Cost EasyDefinition Inspection Scrap Rework Reject SVC LossOpp Sales DeliveryDelay BrandImageDown OfficeLoss OverStorage OverRework Longcycletime DesignChange Potential Additional F Cost Difficulttomeasure Whyshouldwedo6 Quality FailureRate KeyFactorforSuccessof6 NeedTopDownDrive NeedTopmanagement sstrongwillfor6 Topmanagement sstrongandperiodicalannouncementabout6 policy Allemployeesmustparticipate Notonlymanufacturingpart butalsonon manufacturingpartshouldjointheprogramFocusonCustomer srequirements 6 asPan Company scommonstandard Commonlanguage CTQ Cp Z Avoidpersonaltranslationabout6 AllofGoalandtargetarerepresentedas scale Basicprocessforallofprojects HowtoLaunch6 StartatCustomer svoice CTQsfromCustomer svoice Improvetheitemwhichhasbigimpactfirst Ne