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Chapter 5 QM

Six Sigma is a data-driven approach to process improvement originally developed by Motorola. It aims for near perfect processes, products and services with 3.4 defects per million opportunities. The Six Sigma program uses two methodologies - DMAIC which is for continuous improvement and DMADV which is for reengineering processes. DMAIC stands for Define, Measure, Analyze, Improve and Control steps to systematically solve problems. DMADV stands for Design, Measure, Analyze, Design and Validate steps used to design new processes. The Sigma level of a process is calculated using defects per million opportunities (DPMO) formula to measure quality and determine how far a process is from perfection.

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Abdisamed Allaale
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90 views14 pages

Chapter 5 QM

Six Sigma is a data-driven approach to process improvement originally developed by Motorola. It aims for near perfect processes, products and services with 3.4 defects per million opportunities. The Six Sigma program uses two methodologies - DMAIC which is for continuous improvement and DMADV which is for reengineering processes. DMAIC stands for Define, Measure, Analyze, Improve and Control steps to systematically solve problems. DMADV stands for Design, Measure, Analyze, Design and Validate steps used to design new processes. The Sigma level of a process is calculated using defects per million opportunities (DPMO) formula to measure quality and determine how far a process is from perfection.

Uploaded by

Abdisamed Allaale
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd

Six Sigma

Chapter 5
Six Sigma

 Two meanings
Statistical definition of a process
that is 99.9997% capable, 3.4
defects per million opportunities
(DPMO)
A program designed to reduce
defects, lower costs, and improve
customer satisfaction
Six Sigma Program

 Originally developed by Motorola.


 Highly structured approach to process
improvement
 A strategy - DMADV

6
 A strategy - DMAIC
Six Sigma Improvement Methods
DMAIC vs. DMADV

Define

Measure

Analyze
Continuous Improvement Reengineering

Improve Design

Control Validate
DMAIC

DMAIC is a systematic, closed-loop process for continued improvement that is


scientific and fact based

 Define: Define the problem/opportunity, process, and


customer requirements.
 Measure: Define measures (in terms of defects per
million), then collect, compile, and display data
 Analyze: seeks root cause of problems
 Improve: Generate solutions and ideas for improving
the problem.
 Control: verify the stability of the improvements .
Chapter 8 - Project Quality Management 5
Six Sigma DMADV Process

Design:
• Develop detailed design for new process.
• Determine and evaluate enabling elements.
• Create control and testing plan for new design.
• Use tools such as, benchmarking, Quality Function
Deployment (QFD), and cost/benefit analysis.
Six Sigma DMADV Process

Validate:
•Test detailed design with a pilot implementation.
• If successful, develop and execute a full-scale
implementation.
•Tools in this step include: planning tools,
flowcharts/other process management techniques, and
work documentation.
Normal Distribution and Standard
Deviation

Chapter 8 - Project Quality Management 8


Sigma Table

Sigma Yield Defects per Million


Opportunities
1 31.0% 690,000
2 69.2% 308,000
3 93.3% 66,800
4 99.4% 6,210
5 99.97% 230
6 99.99966% 3.4
Chapter 8 - Project Quality Management 10
The calculation of a Sigma level, is based on the number of defects per million opportunities (DPMO).

In order to calculate the DPMO, three distinct pieces of information are required:

a) the number of units produced

b) the number of defect opportunities per unit

c) the number of defects

The actual formula is:

DPMO = (Number of Defects X 1,000,000)

((Number of Defect Opportunities/Unit) x Number of Units)


The actual formula is:

DPMO = (Number of Defects X 1,000,000)

((Number of Defect Opportunities/Unit) x Number of Units)


A manufacturer of computer hard drives wants to measure their Six Sigma level.
Over a given period of time, the manufacturer creates 83,934 hard drives.
The manufacturer performs 8 individual checks to test quality of the drives.
During testing 3,432 are rejected.
Example:

A manufacturer of computer hard drives wants to measure their Six Sigma level.
Over a given period of time, the manufacturer creates 83,934 hard drives.
The manufacturer performs 8 individual checks to test quality of the drives.
During testing 3,432 are rejected.

           

5111.15
  Defects     3432   DPMO   9
  Opportunities 83934   Sigma Level 4.1
  Defect Opportunities per unit 8  
           

1 690,000
Six Sigma Table:
2 308,000

3 66,800

4 6,210

5 320

6 3.4

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