Managing Quality Integrating the Supply Chain S. Thomas Foster

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Managing QualityIntegrating the Supply Chain S.
Thomas Foster
Chapter 14 Six-Sigma Management and Tools
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Strategic Quality PlanningSix-Sigma Management
and ToolsChapter 14

What is Six-Sigma? Organizing Six-Sigma DMAIC overview DMAIC phases The Taguchi method Design for Six-Sigma Using Six-Sigma from a contingency perspective

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Strategic Quality PlanningSix-Sigma Management
and ToolsWhat is Six-Sigma

Sigma (?) is a greek letter used to designate a standard deviation (SD) in statistics Six refers to the number of SDs from the specialized limit to the mean. Six-Sigma about 0.5 of products will not meet specification

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Strategic Quality PlanningSix-Sigma Management
and ToolsWhat is Six-Sigma
Sigma Level Long-term ppm defects
1 691,462
2 308,538
3 66,807
4 6,210
5 233
6 3.4

ppm Parts Per Million

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Strategic Quality PlanningSix-Sigma Management
and ToolsWhat is Six-Sigma

Six-Sigma is designed to handle the most difficult quality problems.

Quality Problems Techniques
90 Basic tools of Quality
lt 10 Six-Sigma
lt 1 Outside specialists
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Strategic Quality PlanningSix-Sigma Management
and ToolsOrganizing Six-Sigma

The key players Champion. Work with black belts to identify possible projects Master Black Belts. Work with and train new black belts Black Belts. Committed full time to completing cost-reduction projects Green Belts. Trained in basic quality tools

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Strategic Quality PlanningSix-Sigma Management
and ToolsOrganizing Six-Sigma

In a company with 100 employees there might be One black belt Sixty green belts Some companies have yellow belts, employees familiar with improvement processes

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Strategic Quality PlanningSix-Sigma Management
and ToolsDMAIC Overview

Stands for Define Measure Analyze Improve Control

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Strategic Quality PlanningSix-Sigma Management
and ToolsDMAIC Phases

Define Four Phases Develop the business case Project evaluation Pareto analysis Project definition

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Strategic Quality PlanningSix-Sigma Management
and ToolsDMAIC Phases

Define Developing the Business Case Identify a group of possible projects Writing the business case Stratifying the business case into problem statement and objective statement

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Strategic Quality PlanningSix-Sigma Management
and ToolsDMAIC Phases

Define RUMBA is used to check the efficacy of the business case Realistic Understandable Measurable Believable Actionable

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Strategic Quality PlanningSix-Sigma Management
and ToolsDMAIC Phases

Measure Two major steps Select process outcomes Verifying measurements

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Strategic Quality PlanningSix-Sigma Management
and ToolsDMAIC Phases

Measure Two major steps Select process outcomes Tools Used Process may XY matrix FMEA Gauge RR Capability Assessment.

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Strategic Quality PlanningSix-Sigma Management
and ToolsDMAIC Phases
Measure Two major steps Verifying measurements Tools Used Use gauges, calipers and other tools. Management System Analysis (MSA) is used to determine if measurements are consistent

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Strategic Quality PlanningSix-Sigma Management
and ToolsDMAIC Phases

Measure Two major steps Verifying measurements Gauge RR Most commonly used MSA Determine the accuracy and precision of your measurements

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Strategic Quality PlanningSix-Sigma Management
and ToolsDMAIC Phases

Analyze Three major steps Define your performance objectives (Xs) Identify independent variables Analyze sources of variability

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Strategic Quality PlanningSix-Sigma Management
and ToolsDMAIC Phases
Analyze Three major steps Define your performance objectives (Xs) Identify the independent variables where data will be gathered Process maps, XY matrices brainstorming and FMEAs are the tools used

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Strategic Quality PlanningSix-Sigma Management
and ToolsDMAIC Phases
Analyze Three major steps Analyze sources of variability Use visual and statistical tools to better understand the relationships between dependent and independent variables

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Strategic Quality PlanningSix-Sigma Management
and ToolsDMAIC Phases

Improve Off-line experimentation ANOVA Taguchi

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Strategic Quality PlanningSix-Sigma Management
and ToolsDMAIC Phases

Control Manage the improved processes using control charts

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Strategic Quality PlanningSix-Sigma Management
and Tools The Taguchi method
Design of Experiment (DOE) Robust design - designed so that they are inherently defect free Concept Design Parameter Design Tolerance Design

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Strategic Quality PlanningSix-Sigma Management
and Tools The Taguchi method
The Taguchi Method provides A basis for determining the functional relationship between controllable factors

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Strategic Quality PlanningSix-Sigma Management
and Tools The Taguchi method
The Taguchi Method provides A basis for determining the functional relationship between controllable factors

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Strategic Quality PlanningSix-Sigma Management
and Tools The Taguchi method
The Taguchi Method provides A procedure for examining the relationship between random noise and product or service variability

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Strategic Quality PlanningSix-Sigma Management
and Tools The Taguchi method
Design of Experiment (DOE) Robust design - designed so that they are inherently defect free Concept Design - examining competing technologies

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Strategic Quality PlanningSix-Sigma Management
and Tools The Taguchi method
The Taguchi Process Problem identification Brainstorming session Experimental design Experimentation Analysis Confirming experiment

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Strategic Quality PlanningSix-Sigma Management
and Tools Design for Six-Sigma (DFSS)
Used in designing new products with high performance Instead of DMAIC DMADV IDOV

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Strategic Quality PlanningSix-Sigma Management
and Tools Design for Six-Sigma (DFSS)
Used in designing new products with high performance DMADV Design Measure Analyze Design Verify

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Strategic Quality PlanningSix-Sigma Management
and Tools Design for Six-Sigma (DFSS)
Used in designing new products with high performance IDOV Identify Design Optimize Verity

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Strategic Quality PlanningSix-Sigma Management
and Tools failure Six-Sigma from a Contingency
Perspective
Reasons for Six-Sigma failure Lack of leadership by champions Misunderstood roles and responsibility Lack of appropriate culture for improvement

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Strategic Quality PlanningSix-Sigma Management
and Tools failure Six-Sigma from a Contingency
Perspective
Reasons for Six-Sigma failure Resistance to change and the Six-Sigma structure Faulty strategies for deployment Lack of data

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Strategic Quality PlanningSix-Sigma Management
and ToolsSummary
The process for Six-Sigma is define, measure, analyze, improve and control Keys to Six-Sigma success are skilled management, leadership and long-term commitment