六西格玛绿带培训教材[001].ppt

版本:1.00日期:May2003,6西格玛绿带培训教材,第一天(定义阶段):-6西格玛及精简优化与COQ的关系COQ的脑力风暴-FirstPassYieldExerciseIIIPO和流程flowdiagram流程analysisofdroppingcardsontotargetRepeatingtheexerciseResults和discussions-西格玛培训中的某些质量改进工具脑力风暴技术第一天wrapup第二天(降低变差):-Thepowerofparetochart和the80/20rulesConstructionofaParetoChartusingcomputer流程flowdiagram和itsassociatedsymbolsTwo实例of流程flowdiagram(usingacommonscenario)Barriersthathinder6西格玛implementation-Break-WhatisFMEAExampleofFMEAGroupexerciseonFMEAofbarriersto6西格玛implementationFMEApresentations-Lunch-,第二天(VarianceReduction):-Conceptofprecision和accuracyHowdoesitlinktothemean和标准偏差Precision和accuracyexample(i.e.Selectionoffundmanager)StatapultexerciseI-Break-Introducingconceptofvariancereduction(i.e.PF/CE/CNX/FMEA/SOP)-Variancereduction脑力风暴exerciseforStatapultStatapultexerciseIIComputationofStatapultexerciseresultaftervariancereductionDiscussionofvariancecontributors-第二天wrapupDAY3(MeasurePhase):RecapofstatisticalterminologyHistogram和anormaldataConstructionofhistogramTransformationofdataCalculateCp,Cpkfromnon-normaldata-Break-,DAY3(MeasurePhase):TheimportanceofgoodmeasurementDirect和indirectmeasurement(i.e.Introductiontoscatterdiagram)Riskofwronginterpretation-Underst和varianceconceptinmeasurementsystem-IntroductiontoGaugerepeatability和reproducibility(GRProject/CandidateSelection,CandidateSelection,Tofillin;Characteristicsof6西格玛candidateScore-sheet和SummaryLeadershipValuesScore-sheet6西格玛CandidatesLeadershipValuesSummary6西格玛Candidates,ProjectSelection,Tofillin;6西格玛ProjectSelectionSummaryEaseofImplementationAssessmentROIImpactAssessment,Candidatesmustscoregreaterthan2.5ptsforeachtoqualify,Candidatesmustscoreatleast0.9ptsintheinthe6西格玛ProjectSelectionSummarytoqualify,6西格玛ProjectSummary,Matchingrightprojecttotherightpeople,Phase2;6西格玛培训和applicationof6西格玛工具s,CollectBaselineDataonProject,yieldCOQCostCycleTimeInventorylevel,Tofillin;6西格玛R0ProjectReviewSheet6西格玛COQTemplate6西格玛ProjectProgressReportTogetallrelevantpartiesapprovalsignatories,Attend6西格玛GB/BBAcademic培训,Applicationof6西格玛工具toProject(s),PF/CE/CNX/SOPsFMEAMSAPARETOPROBABILITYDISTRIBUTIONANOVADOESTATISTICALINTERVALSPC,CreateCertificationTemplate,FollowDMAICPresentationSummaryRevA,tocompleteeachphaseoftheproject,流程to6西格玛GB/BBcertification,Phase3;CertificationofCandidate,CompleteClosureTechnicalReport,Presentationof6西格玛CertificationProject(s),SiteAssessmentofProject(s),IssuePlaque/CertificateAchievementtocandidate,UpdateCandidateLORCareerProfileon培训和Recognition,FinancetoverifyprojectsavingsChampions和MBBtoassesscandidateunderstanding和applicationof6西格玛工具sCandidateCertificationEvaluationForm,流程to6西格玛GB/BBcertification,FinancetoverifyprojectsavingsChampions和MBBtoassesscandidateunderstanding和applicationof6西格玛工具sCandidateCertificationEvaluationForm,RequirementsforCertification,Completionof6西格玛培训courseSuccessfulprojectcompletion(goalachievement和documentation)Demonstrationontheunderstandingof6西格玛工具sEffective和successfulcompletionofstepsto“holdthegain”Completionofeachprojectwithin1yr绿带Certification;completionof2projectswithminimumsavingofUS$25,000perproject黑带Certification;completionof2projectswithminimumsavingofUS$100,000perproject,交付ablesforCertification,Demonstrationofsix-sigmathough流程Completionof6西格玛R0ProjectReviewSheetCompletionof6西格玛ProjectProgressReportCompletionof6西格玛COQTemplateCompletionofDMAICPresentationSummaryCompletionofClosureTechnicalReport,Certification结构,CandidateCertificationBoardSiteLeaderChampionsMaster黑带CertificationBoardReview流程CandidatetodistributetheClosureReportSummarytotheboardatleastoneweekbeforethereviewdate(maybewaivedatthediscretionofthesiteleader)MBBtoactasthechairoftheboardCandidatetopresentprojectdetailsusingusingthought流程mapwithemphasisonhoweach工具wasappliedQuestions,clarifications和reviewbytheboard,Certification结构(cont),BoardmemberstoratecandidateusingCertificationEvaluationFormPassif;CandidateTechnicalAssessmentisgreaterthan20ptsforGreenbelt和greaterthan40ptsforBlackbelt流程Variation和MeasurableResultsEvaluationisatleast4ptsforeachcategoryInformcandidateoftheoutcome,SampleForms,Characteristicsof6西格玛Candidates,LeadershipValuesScore-sheet,SampleForms;LeadershipValuesSummary,SampleForm;ClosureTechnicalReport,SampleForm;CandidateCertificationEvaluationForm,Definitionofa流程A流程isanactivitywhichutilizeinputsfromexternalsource和transformthemintodesiredoutput(s).,Example:Manufacturing流程es(i.e.wirebonding,injectionmolding,glasssawing)Financial流程es(i.e.doublebookkeeping,产品costing)HR流程es(i.e.recruiting,ranking和appraisal,培训)Dailyactivity(i.e.parkingacar,buyinglunch,brushingyourteeth),IPO(Input-流程-Output)Diagram,PeopleMaterialEquipmentPoliciesProceduresMethodsEnvironment,PerformaserviceProducea产品Completeatask,utilizingexternalINPUTStoachievethedesiredOUTPUT(S),Avisualrepresentationofa流程whichlistsinputvariables和outputcharacteristics,WhatisthepurposeofIPO,Ahighlevelinterpretationofa流程,whichenableeaseofunderstanding,throughoutliningthe关系hipsbetweeninputvariables和outputresponse(s).,Whatisadistribution?,Itisapatternformbythecollectionofdata,groupingtheoutcomehorizontally(x-axis),和indicatestheobservedfrequencyoftheoutcomevertically(y-axis).Instatistic,thisgenerateatheoreticalpatternwherebyinformationofentirepopulationcanbeobtainedfromobservinglimitedsamples.,CharacteristicofanormaldistributionIthasasinglepeak和abellshapecurveItisadistributionforcontinuousdata-Themean(average)isisatthecenterofthecurveThevariancedescribethespreadingofdata,为什么isdistributionimportanttoa流程Theoutputofa流程canmostofthetimeassociateswithastatisticaldistribution,givingopportunityforengineertoanalyzethedatastatistically,hencearrivingconclusionwithastatisticalconfidence和atalowercost.,流程CapabilityStudy,流程capabilitypotential,CpBasedontheassumptionsthat:,Cp=流程capabilitypotentialCpk=流程capabilityindexItisameasurementofthecapabilityofa流程,byindexingthe流程naturaltolerancewithrespecttothedevicespecification(i.e.customertolerance),流程isnormal,Itisa2-sidedspecification,流程meaniscenteredtothedevicespecification,Spreadinspecification,Naturaltolerance,流程CapabilityIndex,Cpk,1.Basedontheassumptionthatthe流程isnormal2.Anindexthatcomparethe流程centerwithspecificationcenter,Thereforewhen,CpkCp;then流程isnotcentered,Cpk=Cp;then流程iscentered,Arbitrarysampledataofstarchcontent(gram)in1gramanti-bioticpill,Whatisthemeanstarchcontent?Whatisthevariance?Whatisthe标准偏差?Whatisthe流程capabilitypotential,Cp?Whatisthe流程capabilityindex,Cpk?Whatcanyoudotoimprovethe流程?Theaboveactivityisasigma流程.,Whatcanyouconcludefromthebelow流程?,关系hipbetween流程Capability和DPPM,FirstPassYieldExerciseI,Breakintoteamof9persons.Eachteamconsistof1供应商,1supervisor,3operators,3inspectors和1customer.Theobjectiveisto交付20complete产品tothecustomerThetaskof供应商istosupplycard(i.e.rawmaterial)tothefirstoperator.Thetaskoftheoperatoristodropthecardwithedgefacingdownontothetargetarea,和countthenumberofdropthroughouttheexercise.ThetaskoftheinspectoristoverifythatthecardhasdropwithinthetargetareaIfcardfallwithinthetarget:Passthecardtothenextoperator(ortothecustomerforthelastinspector)Recorddownthenumberofgoodunitsthatarepassedtothenext流程Ifcarddoesnotfallwithinthetarget:Pickupthecard和h和itbacktotheoperatorThetaskofthecustomeristoreceivethe20cards,和recordthetimerequired(i.e.leadtime)Attheendoftheexercise,the供应商willcountthenumberofrawmaterialissuetothe流程,Computationof产品cost,WhatisCostof质量(COQ),Itisthetotalcostincurfromtheresultofpoor质量ofmaterials,产品,流程es,和thecostofnotdoingthingsrightatthefirsttime.,Whatare某些oftheCOQthatyoucanseeatyoursite?,Scrap,Rework,CycleTimeWarranty,Liability,ServiceAudits,Inspections,Evaluations培训withoutROI,ConsultationLostofsales,Lostofmarketshare,Howdoes6Sigma和LeanrelatedtoCOQ?2waystheentirebusiness流程canbeimproved和reduceCOQ:,Toleanupthe流程chain和reducechancesforerror,Toimprovethesigmacapabilityofthe流程,Whataretheoverallyieldforyour流程?,Goingbacktothedroppingcardsexercise,Howcanwereducethe产品cost?Whatisthemainproblemthatassociatetothecostfactor?Knowingtheproblem,whatistherootcausetotheproblem?Canchangingthewaywedothinghelptoimprovethesituation?,FirstPassYieldExerciseII,Breakintoteamof9persons.Eachteamconsistof1供应商,1supervisor,3operators,3inspectors和1customer.Theobjectiveisto交付20complete产品tothecustomerThetaskof供应商istosupplycard(i.e.rawmaterial)tothefirstoperator.Thetaskoftheoperatoristodropthecardwiththesurfacefacingdownontothetargetarea,和countthenumberofdropthroughouttheexercise.ThetaskoftheinspectoristoverifythatthecardhasdropwithinthetargetareaIfcardfallwithinthetarget:Passthecardtothenextoperator(ortothecustomerforthelastinspector)Recorddownthenumberofgoodunitsthatarepassedtothenext流程Ifcarddoesnotfallwithinthetarget:Pickupthecard和h和itbacktotheoperatorThetaskofthecustomeristoreceivethe20cards,和recordthetimerequired(i.e.leadtime)Attheendoftheexercise,the供应商willcountthenumberofrawmaterialissuetothe流程,Whatisthe产品costafterthechangeof流程method,某些质量改进工具in6西格玛培训,ParetoChartGraphicalrepresentationthatdescribecategoriesindescendingoccurrenceorder80%ofaproblemiscontributedby20%ofthecategoriesSeparatetheimportantfewfactorsfromthemanytrivialfactorsExtensivelyusetodefineareastofocusonfordetailanalysis,脑力风暴,Itisthegenerationofideasinagroupsituation,basedontheprincipleofsuspendingjudgement.Aprinciplewhichishighly产品iveinbothindividualorgroupeffort,Effective脑力风暴,Welldefined和clearlystatedproblemAssignarecordertowritedownalltheideasastheyoccurMaintainmanageablegroupsize(i.e5to8persons)Enforcefollowingguidelines:SuspendjudgementEveryideaisaccepted和recordedEncouragepeopletobuildontheideasofothersEncouragewildoroddideas,某些脑力风暴Practices,为什么doIuseit?Tofocusoureffortsontheproblemsthatofferthegreatestpotentialfor改进,Whatisit?Abarchartfornon-numericalcategoriesthatdisplaysattributedatafromhighesttolowestfrequency(basedon“ParetoPrinciple”whichstatesthat80%oftheeffectsaredueto20%ofthecauses),Whatdoesitdo?Identifiesthecausesthatwillhavethegreatestimpactonsolvingtheproblem,IntroductiontoParetoChart,ExampleofParetoChart,ParetoAnalysis,流程FlowDiagram-Makingmycupofcoffee,流程FlowExampleI,流程FlowExampleII,Exercise-:PuttingthemtogetherDevelop流程flowforyourproject,Constructa流程flowchartforyourprojectsMark(*)nexttothe流程orstepwhichisvalueadded和产品iveIdentifythenumberofdecisionboxIndicatethetimerequireineverystepincludingtransportConstructatabletosummarythenumberof产品ive和non产品ive流程,decision和flowPresentyouFlowchart和proposechanges,FMEA(FailureModeEffectAnalysis),FMEA,isaattempttoidentifypossiblefailuremodes和effectsorconsequencesthatfailuremodesmayhaveonperformance,提供ameanofpreventionFMEA提供sanexcellentbasisforclassificationofcharacteristicsItisafundamental工具increatingareliabilitysystemDoyouhaveanFMEAinYour流程?WhenyouhaveaFailuredoyouknowwhatcausesit?,HowdoesFMEAhelpinDailywork,Improvesthe质量,reliability,和safetyof产品IncreasescustomersatisfactionReduces产品developmenttiming和costDocuments和tracksactionstakentoreducerisk,TypesofFMEA,SystemFMEA:Usedtoanalyzesystems和subsystemsintheearlyconcept和设计stages.Focusesonpotentialfailuremodesassociatedwiththefunctionsofasystemcausedbydesign.设计FMEA:Usedtoanalyze产品beforetheyarereleasedto产品ion.流程FMEA:Usedtoanalyzemanufacturing和assembly流程es.DefectFMEA:Usedtoanalyze和prioritize缺陷topreventreoccurrence(in产品和流程es),$305,000IncreasedAnnualRevenue3220MinutesLessMaintenanceDowntime/Machine/Month452,000MorePieceIncreasedAnnual产品ion28LessMaintenanceCalls/Machine/Month15LessSensorFailuresPerYear$7,200AnnualReductioninMaintenance和ReplacementCosts(SourcefromGE,Motorola,Bombardier,ABB,IBMAlliedSignal),FMEABenefits实例From6西格玛Company,FMEA:流程/产品FMEA,SeveritySeverityisanassessmentoftheseriousnessofeffectSeverityisappliestotheeffectonlyThefollowingistheevaluationCriteria,OccurrenceThismeanshowFrequentlythefailuremodeisprojectedtooccurasaresultofaspecificcauseItcanbethoughtofastheprobabilityofoccurrenceofthefailuremodeUseascaleof1(verylow)to5(veryhigh)Frequency,Detection(DET)Assumethefailurehasoccurred;thenassestheprobabilitythatthecurrentcontrolwilldetectthefailuremodebeforethe产品isshippedoutUseascaleof1(verylow)to5(Nil)Detection,PossibleControlsitem:,Fixturefool-proofingSPCinspectionTestinggaugeR&RPreventivemaintenanceOperator培训scheduleStandardoperatingprocedurehumidity/pressure/temperatureControlfiniteelementanalysiscalibrationetc,RiskPriorityNumber(RPN),RPN=SeverityxOccurrencexDetectionNote:Inthemselves,absoluteRPNnumbershavenosignificant.Theyareusefor“Paretorising”orrankingfailurecauses,todecidewhichrequirecorrectiveactions,Sample流程FMEA:FillingPetrolintoCar,WhatisStatistics?,InferentialStatistics,Statistics:Thescienceofcollecting,describing&interpretingdata,The流程ofcollecting,presenting和describingsampledata,usinggraphical工具和numbers,DescriptiveStatistics,The流程ofinterpretingthesampledatatodrawconclusionsaboutthepopulationfromwhichthesamplewastaken,Mean=3