六西格玛绿带介绍(ppt 91页).ppt

1、6 綠 帶 介 紹 Introduction to 6 Green Belt,Content 1. 6 Quality System -Why need 2. 6 - Overview 3. 6 - Methodology 3.1. 6 - Define 3.2. 6 - Measure 3.3. 6 - Analysis 3.4. 6 - Improve 3.5. 6 - Control 4. Conclusion,1. 6 Quality System -Why need 1.1. 從產品飽受競爭威脅的觀點 以美國為例， 1975-1985年，日本挾其反向技術(Reversed Techn

2、ology)優勢，將其高品質的產品推向美洲大陸，使得美國一向以經濟與技術領先的盟主地位發生動搖。,在1970-1989年間美國的市場佔有率： 電視機從50%降至2% 收音機從50%降至2% 汽車從78%降至28% 影印機從90%降至20% 照相機從90%降至5% 鋼鐵從40%降至30% 其結果造成美國貿易赤字每月高達80-100億美元,美國與日本製程能力之比較 年代 美國 日本 製程能力 品質水準 製程能力 品質水準 1970 0.67 2 1.00 3 1980初 4 1980中 4 5 1980末 1990初 Motorola 6方法： 不合格率3.4PPM 相當於 6,美國企業競爭力衰退

3、的原因 美國管理文化中含有不信任的氣氛，這種表現在嚴格的審核、管制、檢查的管理制度上，無形造成過度的管理成本上漲。這種管理監督的作風，大體受到泰勒式科學管理影響的結果。,日本經營之神松下幸之助在一次對美國企業界人士發表演說，提到：你們的公司經營是以泰勒法則為基礎，更糟的是頭腦皆已泰勒化，因此堅信正確的管理，應是管理者在一邊，工人在另一邊，一邊的人只管思考，另一邊的只管工作。給你們一句忠告：管理是執行者將觀念轉移到員工身上的一種藝術。 因此美國開始檢討其品質，各種品質系統亦相繼提出，其中包含6 品質系統。,1.2. 由需求的觀點 在70年代，產品達到2便達到標準。 在80年代，品質要求已提升至3

4、 ，但此標準美國會發生以下事件： 每年有20,000次配錯藥事件 每年有超過15,000個嬰兒出生時會 被拋落地上 每年平均有9小時沒有水、電、暖氣供應 每星期有500宗做錯手術事件,雖然3合格率已達到99.73%的水平，但相信各位對以上品質要求並不滿意。所以有很多公司已要求6的品質管理，其合格品率為99.99966%。 在3水準，由1000個零件組成的產品中，每15個產品中只有1個產品是好的。在6水準則1000個產品卻有996.6好的。 傳統以百分率水準作為設計品質水準，如今變更為以百萬分率(ppm)作為衡量品質的水準。,1.3. 從成本的觀點,1.4. 從時代趨勢的觀點(1),1.4. 從

5、時代趨勢的觀點(2),1.4. 從時代趨勢的觀點(3),1.5. 從品管大師的觀點 J. M. Juran, 1994年在美國品質管理學會年會會上說,“20世紀以生產力的世紀載入史冊, 未來21世紀是品質的世紀”,1.6. 從策點管理的觀點 欲建立及維持組織競爭優勢，效率、創新、品質及顧客回應扮演著主要角色。,1.7. 從近代品質系統的觀點 ISO-9000 Effectiveness: 5 QS-9000 Effectiveness: 10 Malcolm Baldrige Guideline Effectiveness: 25 European Quality Award Effectiv

6、eness: 30, TQM Effectiveness：35 6 -The Little Q Effectiveness: 50 The Ultimate 6 -The Big Q Effectiveness: 90 (上述品質系統均於80年代末期開展出) 6 Work Breakdown Project Team, Project Charter, COPQ,Define Steps (1),Define Steps (2-1) Vision:最具競爭力的企業(GE) Strategy-The Three Circle (GE),Define Steps (2-2) -The Three

7、Circle (GE) Jack Welch (GES CEO)畫三個圓圈：核心、高科技與服務。GE公司未來都要在其中一個圓圈內。公司任何人不再任一個圓圈內者，未來將會被解雇。圓圈外的的事業將被整頓、關閉或出售。三個圓圈的策略讓GE公司找到焦點，不再是集團(似乎什麼都做)。,Define Steps (3),Define Steps (4) CTQ - Critical to Quality 只要是顧客要求的，就是關鍵品質(CTQ)。亦稱為重要成果、特殊限制或流程的Y變數。CTQ係任何會直接影響顧客對產品/服務品質觀感之因素。顧客在乎的事，就是企業或組織在乎的事。新點子要採納外部觀點(Outs

8、ide-in Perspective)，即從顧客的眼光來看企業或組織的一切。,3.2. DMAIC Methodology 5 Stages DMAIC Methodology and Statistical Tools Phase: Measure Steps; Work Breakdown Graph Analysis, Capability Analysis, Confidence Interval,M1 Specify Project M1 step covers the followings: CTQ Breakdown Define Scope Process Mapping Pa

9、reto Analysis Define performance index and specifications,The success of any 6 activities relies mostly on the CTQ definition and selection,Define Performance Index,Example of Performance Index Yield Cycle time Defect rate Machine failure rate Customer stand-by hours Number of invoice errors Elapse

10、Time from loan application to money transfer to the customer account Hours taken from receiving order to delivery to the customer,M2 Measurement System Analysis M2 step covers the followings: Statistic fundamentals Sampling plan Data collection plan Variation of measurement system Gage R Anything th

11、at results in nonconformance) DPO: Defect per Opportunity DPMO: Defect per Million Opportunities,Example of Sigma calculation: Discrete Data Case (1): Over the last several years, you have collected data on trips to the airport. Of the 100 trips sampled, you have missed only 5 flights. If you indica

12、te this situation as Sigma level, what will it be? Sol. DPU = DPO =5/100 = 0.05 1-0.05 = 0.95, Z = 1.65 level = Z + 1.5 =1.65 + 1.5 = 3.15,Case (2). An accounting term conducted an internal audit for the financial report of year 2001 and they observed 25 nonconforming record. There were 2 steps of p

13、robable incorrect entry identified in the process and the total observation was 25,000 records. What is DPO? What is DPMO? What is Sigma level of financial reporting process? Sol. DPU = 25/25000,DPO = 25/(2*25000) =0.002, DPMO = 0.002*106 =2000 1- 0.002 = 0.998,Z = 2.878 level = Z + 1.5 = 2.878 + 1.

14、5 = 4.378,Example of Sigma calculation: Continuous Data(1),Continuous Data(2),(1) Mathematical Model；(2) Continuous；(3) Smooth；(4) Symmetrical; (5)Tail asymptotic to X-axis；(6) Bell shaped；(7) Mean = Median = Mode (8) Total area under curve = 1,(1) The normal distribution has the following propertie

15、s. 68.27% of the data fall within 1 95.45% of the data fall within 2 99.73% of the data fall within 3 (2) In order to assess the quality of the process, we must compare the process characteristics (via the location, spread and shape) to the specification limits and targeted value.,Continuous Data(3)

16、 Standardization of Normal Distribution The Sigma of a Process is the number of standard deviation between the mean and the Specification Limits.,Measurement System and Measurement Error(1) Measurement system is viewing as a process. Sources of variation: 5M1E Validate possible sources of variation

17、in the measurement process,Variation in measurement System,Measurement System and Measurement Error(2),Process Variance,Gage R Work Breakdown Regression, Hypothesis Test, ANVOA, Multi-Vari Analysis,A1 Set Up Improvement Goal In M3 the current product capabilities were defined. Step A1 provides the t

18、ools to define performance objectives. The purpose is to set objective to establish a balance between improving customer satisfaction and available resources.,A1 step covers following topics: Establish performance goals Assess short-term and long-term sigma in terms of measurement benefits (decrease

19、 in COPQ, increase in revenue) Determine improvement direction by the gap analysis between goal and current level,Paths to Performance Goals,Benchmarking - Why Benchmark (1)?,Benchmarking - Why Benchmark (2)? Develop and Improvement Strategic Goals Establish actionable objectives Provide sense of ur

20、gency Encourage breakthrough thinking Create a better understanding of your industry,A2 Identify Potential Causes Finding main independent variables, and making the listY = f (X) Object Make list of potential independent variables for changing Work Breakdown Operating Window, Responsibility Matrix,I

21、1 Identify Vital Few In analysis step, potential Xs were identified with a possible prioritization as to their importance in controlling Y. Improve step provides tools to explore and uncover the vital Xs and how much impact each X has on the response Y. One of the major tools used for both explorati

22、on and confirmation of the effect of Xs on the Ys is experimental design (DOE). By experimentally manipulating the independent variables, DOE provides an efficient and economical means for reaching valid and relevant conclusions about a process.,Types of Experimental Design,Screening Full factorial 2K factorial Fractional factorial Optimization Multi-level experiments Composite design Response surface method,I2 Formulate Optimum Model The vital few important Xs were identified and characterized in I1. The tools in I2 follow a methodology for establishi