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1、1 SixSigmaByDanielWuFordLioHoMotorCompany 2 Outline QualitylevelWhatisSixsigma WhyweneedSixsigma DevelopmentandDeploymentstrategyHowSixsigmamergesintoourdailybusiness 3 Overview FourQualityGurus HistoricallycompanieshavefocusedonqualityissuesforcustomersatisfactionPriortosixsigmatherewerefourkeyqual
2、itygurusthatmostcompanies qualityprogramsfollowedDemingJuranCrosbyTaguchi 4 Deming Demingtaught ImportanceofunderstandingvariationinworkprocessesRoleofmanagementinleadingforqualityApplicationofstatisticsPlan Do Check Act 5 Deming sContributiontoProfitability EXTERNAL INTERNAL CUSTOMERSATISFACTION MA
3、RKETSHARE PROFIT PRODUCTIVITY QUALITY Betterproducts services Improvedprocesses Competewithvalue PRICE CompetewithPrice Decreasedcycletime Eliminateset uptimes COST Opportunityforprofit PRODUCTQUALITY PROCESSQUALITY Reducerework Eliminatein processinspection Reducescrap Increaseproductlife Eliminate
4、incomingtesting Plan Do Check Act 6 Juran Jurantaught BreakthroughperformanceParetoeffectImportanceofmanagementprinciplesQualitybydesignandplanning 7 Juran sContribution Planning CostofPoorQuality Percentofoperatingcosts ProductionBegins Originalzoneofprocesscontrol Newzoneofprocesscontrol 0 20 40 0
5、 Control Time Improvement LessonsLearned Sporadicspikefromobservedproblem ChronicWaste anopportunityforimprovement Control SpecialcausevariationCommoncausevariation 8 Crosby Crosbytaught CustomerrequirementisperformancestandardQualitymaturityisajourneyPreventiveactionasbasicapproach 9 Taguchi Taguch
6、itaught CostofpoorqualityislosstosocietyasawholeRobustqualityisdesignedforconsistentproductionDesigncontrolismoreimportantthanproductioncontrol 10 Taguchi sContribution LowerSpecificationLimit UpperSpecificationLimit NominalValue RegionofCustomerComplaints RegionofCustomerComplaints RegionofQuestion
7、ablePerformance RegionofQuestionablePerformance RegionofSpecifiedPerformance Mean LowerControlLimit UpperControlLimit RegionofDesiredPerformance Cost 11 WhatAretheLimitstoImprovement 2Sigma 3Sigma 4Sigma 5Sigma 6Sigma BasicQualityTools StatisticalTools DesignforSixSigma DFSS CleanSheet 12 Challengei
8、nthemillennium Questionconfrontingbusinessleadersandmanagers Itisnot Howdowesucceed It s Howdowestaysuccessfully 13 Change Itisnotthestrongestthatsurvive northefittest butthosemostabletoadapttochange CharlesDarwinTheOriginofSpecies Peopledonotresistchange peopleresistbeingchanged Beckhard 14 Challen
9、ge Resistance theuniversalreactiontochange TechnicalresistancePoliticalresistanceOrganizationalresistanceIndividualresistance 15 SixSigma SixSigmaisnotabusinessfadtiedtoasinglemethodorstrategy butratheraflexiblesystemforimprovedbusinessleadershipandperformance Itisnotabouttheory it saboutaction Pass
10、ion Execution FastandLastingResults SixSigmaFocus DelightingthecustomerthroughflawlessexecutionRapidbreakthroughimprovementAdvancedbreakthroughtoolsthatworkPositiveanddeepculturechangeRealfinancialresultsthatimpactthebottomline Sigmaisastatisticalunitofmeasurethatreflectsprocesscapability Thesigmasc
11、aleofmeasureisperfectlycorrelatedtosuchcharacteristicsasdefects per unit parts permilliondefective andtheprobabilityofafailure error DistributionShifted 1 5s 2 308 537 3 66 807 4 6 210 5 233 6 3 4 s PPM ProcessCapability DefectsperMillionOpp SixSigmacorrespondstopartsperbillionifprocessiscentered Si
12、xSigma Goal 3Sigma 6Sigma 5Sigma 4Sigma 93 32 99 379 99 9767 99 99966 Historical Current Intermediate Long term Sigma Long TermYield Standard SixSigma PerformanceTarget ToProduce ImprovedRolledThroughputYield DefectsPerUnit DefectsPerMillionOpportunityReducedCostofPoorQuality COPQ ImprovedCapacityan
13、dProductivity ReducedVariationInOurProcesses Products s AProblemSolvingMethodology CharacterizeOptimizeBreakthrough T USL LSL USL LSL TheStrategy CustomerFocused BothInternally Externally WhichBusinessFunctionNeedsIt Aslongasthereisaprocessthatproducesanoutputwhetheritisamanufacturedproduct data ani
14、nvoice etc wecanapplytheSixSigmaBreakthroughStrategy Fortheseprocessestoperformtoacustomerstandardtheyrequirecorrectinputs 6SigmaMethods MFG DESIGN SERVICE ENG MAINT ADMIN QA PURCH Dataisderivedfromobjects situations orphenomenonintheformofmeasurements Dataisusedtoclassify describe improve orcontrol
15、objects situations orphenomenon 1 Weonlyuseexperience notdata 2 Wecollectdata butjustlookatthenumbers 3 Wegroupthedatasoastoformchartsandgraphs 4 Weusecensusdatawithdescriptivestatistics 5 Weusesampledatawithdescriptivestatistics 6 Weusesampledatawithinferentialstatistics LevelsofAnalysis Whatlevela
16、rewe TheFoundationoftheSixSigmaTools 23 TheRoleofSixSigma Sixsigmaisthebestmeanstorealizethephilosophy values andgoalsassociatedwithyourbusinessinitiatives Region BA 6 LinkingPins BusinessAreaInitiatives Itunifiestheinitiativesandprovidesacommonlanguagewhichallpeoplecanunderstandandspeak HowDoWeImproveCapability OurOutputs Y s aredeterminedbyourInputs X s IfweknowenoughaboutourX swecanaccuratelypredictYwithouthavingtomeasureit Ifwedon tknowmuchaboutourX s thenwehavetoresorttoinspectionandtest no
