Six Sigma

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• Six Sigma
• What is it?

Robert Fruit SSBB CQE
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Page I 2 Guaranteed Success
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Page I 2 Define the Problem
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Commercial Airline Take Off

• Pilot walks around the plane
• Alaska Air plane crashes because of failed
  cable to vertical stabilizer
• Pilot checks controls from cockpit
• United Air Lines plane runs out of fuel when
  captain asked for gallons of gas and was given
  litters of gas
• Pilot goes through lengthy check list
• All procedures have historical reasons
• Have some procedures outlived their usefulness
• This procedure has 6 s level of success, it is
  not Six Sigma

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Six Sigma is a Process for Improvement

• Six Sigma is different than the procedures that
  preceded it
• Emphasizes that you must have top management
  involvement from the start
• Always has a limited time frame
• Has a written goal
• Has determined a means to measure success

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DMAIC

• Define
• Measure
• Analyze
• Improve
• Control

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Six Sigma is about Measuring

• Six Sigma is all about measuring to prove results
  and improved profit. It is also about shaking
  things up. An organization not willing to change
  is not prepared to start a Six Sigma project

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Make no Arbitrary Decisions

• Six Sigma is based on measured values
• Many of those measurements are statistical
• there are many degrees of probability, some
  nearer the truth than others
• Christian Huygen 17 century from
• Absolute Zero, Shachtman, 1979

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Not every problem is a Six Sigma issue

• Daily issues are no Six Sigma issues
• Opened ended problems are not Six Sigma issues

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Six Sigma issues have defined periods

• Part of defining a Six Sigma issues is setting a
  time limit for the Six Sigma effort.
• Typical time period is 3 months
• Some have less time
• Rarely does a Six Sigma effort have more than 9
  months

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Where to Start

• Look for KIPV (Key Input Variables)
• That effect KOPV (Key Output Variables)

• KIPV
• Things that influence KOPV
• KOPV
• Things that are important to your customers

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Voice of the Customer

• KOPV is the voice of the customer
• If it is important to the customer it is a KOPV
• Appearance
• On time delivery
• Meet its requirements
• support

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Who is the customer

• The person outside your company who buys your
  product
• The person inside your company who uses your
  product next
• Both

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The Purpose of Business

• Take a product
• Perform your procedures on it
• Increase the value of the product
• Have a customer (internal or external) who is
  willing to buy that increase value

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Where did Six Sigma Begin

• Motorola made Quasar TVs in Chicago
• Lost money on every set that left the plant
• Problems with quality of sets
• Problems with worker motivation
• Sold Manufacturing plant to a Japanese firm
• Got workers involved in manufacturing process
• Reduce defect to 1/20 of former level
• Same plant, same workers
• Made big profits
• Motorola was embarrassed
• CEO swore never to let this happen again
• Started people on the path that became Six Sigma

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GE gets into Six Sigma

• Under Jake Walsh GE starts to use Six Sigma
  methods
• One of the biggest money savers was in reports.
• People went around and talked to managers about
  the mountain of reports they got every month
• Found that only a few of the reports were
  actually used
• Eliminated unused reports
• Estimated savings about 1 billion per year

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TQM

• Who remembers TQM
• It tended to be a top down system
• Upper management demanded better quality from the
  people who worked for them
• Who remembers Quality is our business
• TQM tended to be short term attention
• As soon as quality problem solved move onto next
  project
• Lack of follow up

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Six Sigma is Long Term

• Get top management involved from the beginning
• Clearly define the problem
• Measure performance
• Measure results of improvements
• Report on saved by improvements
• Set up system to monitor results after project is
  concluded

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The Cost of Poor Quality

• Many companies operate at 3-4 s levels
• 25-40 of revenue used for fixing defects
• Rework parts
• Sorting out defective parts
• Scrape
• Extra employees
• Most of these companies dont realize what poor
  quality is costing them
• Companies working at 6 s level typically spend 5

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Probability and Central Tendancy

• Typical show single probability curve
• The central tendency can shift from the ideal
  position
• This increases the area in the tail regions which
  is a measure of defects

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Six Sigma Defects per Million

• Allow the central tendency move by 1.5 standard
  deviations either side of theoretical perfection
• Page II-3

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Defects per Million Opportunities

• DPP Defects per part
• DPP defects / parts
• O Number of opportunities for a defect per part
• DPMO DPP / O 1,000,000

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Six Sigma 3.4 DPMO

• Achieving Six Sigma level is having 3.4 DPMO
• Measure defects at start of process
• Convert to s level
• Measure defects after improvement
• Convert to s level

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Six Sigma is more than DPMO

• DPMO in manufacturing
• DFSS Design for Six Sigma
• New process designed to meet Six Sigma from the
  beginning
• Lean Manufacturing
• In general almost anything that significantly
  improves profits

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Punch Press Problem

• Bid on project based on 100 parts per minute
• Best they can achieve is 80 parts per minute
• They were going to loose a lot of money on the 3
  year contract

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Hand placed

• The pieces over lap each other
• Must be precisely placed for machine pickup at
  customer
• NO DEFECTS allowed in trays

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80 Pieces Per Minute

• Punch press no defective parts
• Operators must untangle parts on round table
• Operators barely keep up with flow of parts
• Unstack tray for parts

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Process Flowchart
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Things Under Consideration

• Process Issues
• Improving manual packing methods
• Un-stacking of delivered trays
• Running machine at 180 SPM
• maintain current quality
• Using 2 inch or 3 inch stroke press
• Staging and storage of trays
• Analyzing cost of materials

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Change Packing

• Receive 1,000 trays to a box
• Hard to unpack from shipping box
• Trays cling together
• Must be separated without distorting box
• Come from Phoenix
• Send 16 trays out in special boxes
• Arrange for local manufacture of trays
• Receive in the same boxes used to ship product

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Change Personnel Layout

• Tests showed that packers on linear conveyor
  packed faster
• Parts did not stack on each other

Improved personnel layout
Original personnel layout
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2
3
3
1
4
4
1
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Original Costs
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Improved Costs
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Improved Profits
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Some Keywords

• DMAIC
• Voice of the Customer
• KIPV
• KOPV
• DPMO

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High Definition Television
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HD TV on a computer

• ATI makes a HD tuner for PCI slot HDTV Wonder
• Works only with broadcast HD signal
• Minimum standards do not come close to describing
  computer requirements
• Do not get without having AGP 8x or PCI express
  slot
• Designed to be part of multi-media computer
• Has remote control, USB plug in receiver

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Extreme Tech Comment
The card itself features a Philips HDTV tuner box
but ATIs NXT2004 receiver chip does much of the
heavy lifting. The NXT2004 VSB (vestigial
sideband modulation)/QAM (quadrature amplitude
modulation) Receiver is designed for off-air and
cable digital television receivers, set-top
boxes, PCDTV, and datacast applications where
cost, low power and industry-leading performance
are a must. The NXT2004 Multimode VSB/QAM
demodulator can work in either the ATSC
compliant 8 VSB mode for terrestrial
broadcasting, or DICSIS-compliant 64 QAM or 256
QAM modes for Digital TV-Cable Connect and
Digital TV Cable Interactive reception. However,
in the HDTV Wonder product, the NXT2004 is set up
only as a 70-channel off-the-air HDTV receiver
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ATI HDTV Card
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HDTV is not CPU hog

• 2.8 G-Hz celeron
• 768 Meg Ram
• 7200 RPM HD
• No AGP
• No PCI express
• 720P black image
• 1080i black image
• Demand Direct X 9
• Plus more

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ATI RADEON 9250 PCI
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Things I have Learned

• If you go for HDTV Wonder you are still in the
  pioneer era (arrows in the back)
• The card assumes you are creating a media
  computer (rich set of software features)
• Remote control plus USB RF receiver
• Needs tweaking to start HD TV
• S video and component Video, left, right input
• Not every feature works as well as you would like
• TV directory
• Create DVD disk
• Keep it all ATI (HDTV and video card)
• Complaints about GE-Force video cards

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And now to Robts

• There are children ready robot projects
• No not the False Maria
• Based on BASIC Stamp module

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2 Robots
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BASIC Stamp
Serial SignalConditioningConditions
voltagesignals between PC serialconnection (/-
12V) and BASIC Stamp (5V) for Programming.
5V RegulatorRegulates voltageto 5V with a
supply of 5.5VDC to 15VDC
EEPROMStores the tokenized PBASIC program.
ResonatorSets the speed at whichinstructions
are processed.
Interpreter ChipReads the BASIC program from the
EEPROM and executes the instructions.
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BASIC Stamp
Pin 1 SOUT Transmits serial data during
programming and using theDEBUG instruction
Pin 24 VIN Un-regulated input
voltage (5.5-15V)
Pin 23 VSS Ground (0V)
Pin 2 SIN Receives serial data during
programming
Pin 3 ATN Uses the serial DTR line togain the
Stamps attention for programming.
Pin 21 VDD Regulated 5V.
P0
P15
P1
P14
Pin 4 VSS CommunicationsGround (0V).
P2
P13
P3
P12
P4
P11
P5
P10
P6
P9
P7
P8
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BOE BOT Box
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Board of Education Robot BOE Bot
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BOE BOT Circuit Board
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BOT motherboard

• The Board of Education makes it easy to connect
  devices, power up and program.

5V regulator
Battery
Servo Connections
Wall DCSupply
Power Header
Power OnLight
I/O Header
Breadboard
Serial ProgrammingPort
Reset Switch
Off/Module Power/Servo Power
Off/Module Power/Servo Power
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Programming

• A program is writtenin the BASIC Stamp Editor.

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Instructions
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Instruction

• The FREQOUT command sends high/low signals to the
  specified pin at the frequency and for the
  duration defined.FREQOUT Pin, Duration, Freq1,
  Freq2
• To play a note at 2000Hz which lasts 1.5 seconds

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Instructions
Inner Loop
Outer Loop
The inner loop is performed fully
everyrepetition of the outer loop.
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Instructions
When index 0
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Instructions
When index 1
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Instructions
Each CASEwill be checked
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Shows how resources are used

• View memory
• View registers

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BOE BOT Program

• 'Robotics with the Boe-Bot - BoeBotForwardTenSecon
  ds.BS2
• 'Make the Boe Bot roll forward for 10 seconds
• 'STAMP BS2
• 'PBASIC 2.5
• counter VAR Word
• FREQOUT 4, 2000, 3000 'create sound
• FOR counter 1 TO 407 'forward 10
  seconds
• PULSOUT 13,850 'left wheel
  forward
• PULSOUT 12,650 'right wheel
  forward
• PAUSE 20
• NEXT
• END

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SUMO BOT Box
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SUMO BOT
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Sumo Bot
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SUMO BOT Circuit Board
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SUMO Bot 2 CPU

• Motion uses PIC16C505 processor for wheels
• Simplifies motion commands

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SUMO BOT Programming

• Simpler commands because of built in functions
• Must include predefined constants

PAUSE 100 RobotData RobotForward GOSUB RobotSend
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SUMO BOT Remote Control
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Remote Control Details
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Pretend it is like Sojourner
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Where to go from here
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Which Bot do you want

• BOE BOT
• More hardware assembly
• Must adjust software to hardware performance
• Comes with lots of extra parts
• More learning opportunities
• SUMO BOT
• Quick assembly
• Starts running immediately
• 4 built in behaviors
• Remote control
• Kids like simpler requirements better