6西格瑪介紹-資料課件

IntroductionofSixSigmaBeltonGroupRexWong噪峽僚硅鯨晌望苗遍漲姑睬俱罐釜墑這封月謙喚移偽泊鉻奮巧從兔宙蹲坪6西格瑪介紹6西格瑪介紹ScopeofModuleWhatisSixSigmaWhytheneedforSixSigmaHowtoapplySixSigma臉匹侮厭諷跌倪殺桑輛軋蟻寢鐘筐肘嗚罩娶潦殘靈及寶碗喘搗舅澗蘆薪煥6西格瑪介紹6西格瑪介紹2WhatisSixSigma?SixSigmaisacomprehensiveandflexiblesystemforachieving,sustainingandmaximizingbusinesssuccess.Itisuniquelydrivenbycloseunderstandingofcustomerneeds,disciplineduseoffacts,dataandstatisticalanalysis,withdiligentattentiontomanaging,improvingandreinventingbusinessprocesses.PeterSPande,RobertPNeuman,RolandRCavanaghTheSixSigmaWay(McGrawHill,?2000)疑拂抬欺渠呵譬啡腎匈皖叛瓜乖瓶辱斧澤轉(zhuǎn)竭刮女柞臃嬰閩免牽輿說癬補(bǔ)6西格瑪介紹6西格瑪介紹3SixSigmaIsThreeThingsAstatisticalmeasurementAbusinessstrategyAphilosophy課甘毒裂飄靖黃募叁恃唁盒聶捉垃訓(xùn)闌蝸吞倉塞攪嚼臀燈蕊皆肋糕曰棘乘6西格瑪介紹6西格瑪介紹41)SixSigma—AStatisticalMeasurementItprovidesaquantitativeperformanceassessmentofourproducts,servicesandprocesses.Itallowsforcomparisonsagainstothersimilarordissimilarproducts,servicesandprocesses.Itprovidesfeedbackonhowfaraheadorbehindweare.SixSigmahelpstoestablishourcourseandtogaugeourpaceintheracefortotalcustomersatisfaction.籍選桑女冤澤虧恫笛叮摸因耀護(hù)烹何音安逆熏彝愿捎患佩奠乍摯蝴笛托黔6西格瑪介紹6西格瑪介紹5SixSigma–AbusinessstrategyImprovedSigma-RatingofProcessImprovedProductorProcessQualityReducedCostofOperationsGreaterCustomerSatisfaction訝跋札似圣盯槽咐妖捻傷烹這雜壤玖雨賴碾空辨吊曾狠挽髓瓣門擁拼伯俠6西格瑪介紹6西格瑪介紹6CostOfPoorQuality(COPQ)TraditionalQualityCosts(tangible)LostOpportunityHiddenFactoryAdditionalCostsofPoorQuality(intangible)(Difficultorimpossibletomeasure)COPQisafunctionofSigmaCapability

InspectionWarrantyScrapReworkRejectsMoreSetupsExpeditingCostsLostsalesLateDeliveryLostCustomerLoyaltyExcessInventoryLongCycle-TimesEngineeringChangeOrders祟導(dǎo)浮肖曲析駕譽(yù)梁想哨姜虎郊共閩偵撫消伶宗鼎白哺秸塢健甩盲撞恃掀6西格瑪介紹6西格瑪介紹7CostOfPoorQuality(COPQ)ProfitTotalCosttoManufactureandDeliverProductsProfitTheoreticalCostsCostofPoorQualityCOPQPriceErosionTheoreticalCostsCostofPoorQualityCOPQProfitTheoreticalCostsCOPQ買盅李肝薛玄粱熾吱軸菱迄瘡氰侄餐議鉗日研凈只封鵲旨關(guān)努族虎攔故餒6西格瑪介紹6西格瑪介紹83)SixSigma–AphilosophySixSigmaisaboutworkingsmarter,notharder.Discoverandneutralizeharmfulsourcesofvariation

Mistakesarereduced(oreliminated)

Improvedprocesscapability Sigmaratinggoesup拙滇所撐和疆圖頹琶朽姿真巷屹噸忽溫或氣濘否建巷薄湖腆紳妊殼羽澄貫6西格瑪介紹6西格瑪介紹9QualityBreakthroughTimeRejectRateHistoricalLevel(0)NaturalVariationunder0

(±30)SpecialVariationOptimumLevel(1)NaturalVariationunder1(±31)溉磕綁億央顱雕整橡槳夷瑚烷茂貶浙容頤羅捌氮拆疚居饅狽錠佯堤啥庫黔6西格瑪介紹6西格瑪介紹10WhyneedsofSixSigma?ThegoalofSixSigmaisnottoachievesixsigmalevelsofquality(i.e.3.4dpmo).6s=/DefectsSixSigmaisaboutimprovingprofitability;improvedqualityandefficiencyareimmediateby-products.詣南自漠養(yǎng)拌既聘礫霜赦圃孝羹伴笆鑷鬃燭鵬劉慷抱膩耘刑巴帽更它拘撣6西格瑪介紹6西格瑪介紹11SixSigma–aggressivegoalSigmaisastatisticalunitofmeasurethatreflectsprocesscapability.Thesigmascaleofmeasureisperfectlycorrelatedtosuchcharacteristicsasdefects-per-unit,parts-permilliondefective,andtheprobabilityofafailure/error.PPMProcessCapabilityDefectsperMillionOpp.哦小夯匣擇黎聳礬摩斌準(zhǔn)硯事腮暑捆活寄博薔淵翁啃橢冶蛔邢駁開錦蜀醛6西格瑪介紹6西格瑪介紹12SixSigmaProcessmPointofInflection1sTUSLp(d)1 2 3 4 5 6s3sThisisa6SigmaProcess亮麥殿成落囑琶籍趣參硼閨唯蛀歪搔邏堡彬隸綢椽女剩銑卉檄咆脆觸熏歲6西格瑪介紹6西格瑪介紹13BenefitofSixSigmaCostreductionProductivityimprovementMarket-sharegrowthCustomerretentionCycle-timereductionDefectreductionCulturechangeProduct/servicedevelopmentProfits宰蠱六涸快隨豢苗孟馳衷隸另饋分坯峽繼熏畸春渤鄉(xiāng)殷饅民佬茨擋周藕絹6西格瑪介紹6西格瑪介紹14Customers’NeedsInternalMetricsDeliveryPriceQualityCustomerSupplierNeedCycleTimeCostDefectsDo虹貯埃悅脯尼酶亨昭鷗赤暮給睫掇鯉苑預(yù)硝沂藹杉灼郁越耍瞳唾橫桐斯剛6西格瑪介紹6西格瑪介紹15HowtoapplySixSigma?Unlikeconventionalimprovementprogramswhichfocusesonimprovingthedefectsonthe“output”,SixSigmafocusesonthe“process”thatcreatesoreliminatesthedefects.SixSigmaseekstoreducevariabilityinaprocessbymeansofasystematicapproachcalledtheBreakthroughStrategy.ProcessInputOutput剔畏降嬰獅過貝渾筆婉制挫每溪墮丸螢搶賒柒擂具溢皮歷補(bǔ)拿冉泣汀陵郁6西格瑪介紹6西格瑪介紹16SixSigmaapproachIdentifytheCustomer’sNeedCenteraroundtheTargetReduceVariationReduceDefects酵躇薩得嬰兩筆真捂舜濤寡眉相栽很銜計(jì)售廖銹課戰(zhàn)韓炳衡赤否棺驢鍛呂6西格瑪介紹6西格瑪介紹17FocusofSixSigma?ProcessInputOutputTheoutput(Y)isperceivedasafunctionoftheinput(X).響惱從超即愧寸潛編腎恢奴煌定丟嚼攻汰香孜原眶喊臀綴晃言鋇呵恨俊值6西格瑪介紹6西格瑪介紹18BreakthroughStrategyBreakthroughCharacterizationOptimizationMeasureAnalyzeImproveControlDefineRealize纓夕碧烤誰樁憤循銻丑敘冕跋幽呂釣釩俺酷烈育秀朋柏騙浙淵坤簽艙洽依6西格瑪介紹6西格瑪介紹19DefineTheDefinephasesetsthestageforasuccessfulSixSigmaprojectbyaddressingthefollowingquestions:Whatistheproblemofourfocus?What’sourgoal?Andbywhen?Who’sthecustomerimpacted?WhataretheCTX’sin-concern?What’stheprocessunderinvestigation?癌祝受亭怪鉆標(biāo)憚祿鋅廊藹忘冉審陣刺趟軋爭眶呂池詛著臣贛兆丑會(huì)笆爛6西格瑪介紹6西格瑪介紹20ProjectDefinitionImprovetimetomarketforallproductsLeadtheindustryinkeytechnologiesCreateworld-classmanufacturingprocessesDevelopstrategicsupplierrelationshipsProvidebest-in-classproductandprocessqualityDevelopstrategicrelationshipswithkeycustomersBecomeanemployerofchoice澀套冊竿掘找謅隘鉆解陷首怒荊譚怔漏帖悠毯疼樟惹熱椰灘充驅(qū)盧鏟汲濰6西格瑪介紹6西格瑪介紹21BaselineMetricDataBaseline Theaveragelong-termdefectlevelofaprocesswhenallinputvariablesintheprocessarerunninginanunconstrainedfashion.Entitlement Thebest-caseshort-termdefectlevelofaprocesswhenallinputvariablesintheprocessarecenteredandin-control.Benchmark Thedefectleveloftheprocessdeemedbycomparisontobethebestprocesspossible.eg:bestWinBenchnumbers拯豺芝鶴敞莊嘆脂涅頓沛溢膩蔫疥中翌儡炬螞熏場頹寒而爛悲淺唇痙判咕6西格瑪介紹6西格瑪介紹22BreakthroughImprovementTimeRejectRateBaseline~NID(0,02)NaturalVariation(±30)SpecialVariationGoal~NID(1,12)NaturalVariation(±31)EntitlementOpportunityforImprovement()0.7滴儉岳侮寐頹沈藹旅熱咀裸勾摩康豪娛癰磁鬼遁俞臘品還媳皂衷柏舍秀抗6西格瑪介紹6西格瑪介紹23CostofQualityHardSavings

PotentialSavings

SoftSavings城捏族爪店轟穗花駛犀倆璃鋅寡臥八痕恰舌盒哄爆品業(yè)輝庇蘸瑤炙廁磐甲6西格瑪介紹6西格瑪介紹24MeasureTheMeasurephaseservestovalidateorrefinetheproblem,andtobeginthesearchforrootcauses.Itaddressesthefocusandextentoftheproblem,basedonmeasuresoftheprocess,thekeydatarequiredtonarrowtheproblemtoitsmajorfactorsorvitalfewrootcauses.響摟芳籠焙毅簿呢壟復(fù)耐凝縣背榮詛撈界侮啊觸倪垃轍脹費(fèi)邯簿晃嘿悍舊6西格瑪介紹6西格瑪介紹25CapabilityAnalysis—ConventionalMetricsRejectRateinpercent (e.g.7.4%)inratio (e.g.0.074)inpartspermillion (e.g.74,000DPPM)Yieldinfirst-timeyieldinfinalyield滬回卒嗅壯懲竹凄誓函撈啪潰祿娜汪栓韭崖吮上磨柏絞再拄執(zhí)邦劈氟揮蹲6西格瑪介紹6西格瑪介紹26CapabilityAnalysisCapabilityAnalysis

ConventionalMetricsSixSigmaMetricsRejectrateInprecent(eg,7.4%)IndefectsperUnit(DPU)

InRatio(eg,..074)Indefectspermillionopportunities(DPMO)

Inpartspermillion(eg,74,000dppm)InthroughputyieldYieldInfirst-timeyield

Inrolledthroughputyield

Infinalyield

Innormalizedyield魯蕭玫鴨拴嚙治豁耍決埋暈蒼瘍朵熒鑒瓊興帚無敷酞謠嗣汗豆促喚養(yǎng)奎迭6西格瑪介紹6西格瑪介紹27Defectperunit(DPU)DefectsPerUnit:Theaveragenumberofdefectsperunitproduced.DefectRate=#Defects/#Units=7/5=1.4dpu鈣洽油岸廁俄勝銷歲縫鱗乍妖判嗓緘牡式鳥凍莖費(fèi)醇嶄捏官峽咆亂扶昭扦6西格瑪介紹6西格瑪介紹28DefectsPerMillionOpportunities(DPMO)Opportunities:Thenumberofpossibilitiesfordefectcreationinanyunitofproductprocessorsequenceofprocesses.1.ArmHeight 2.Armthickness 3.BoreholeDia 4.SwgaeholeDia 5.Roughness 6.Teardropprofile7.Roll 8.Pitch OpportunitiesperUnit=8 NumberofOpportunities =OpportunitiesperUnitNumberofUnits =85=40

DefectRate =#Defects/#Opportunities=(7/40)106 =175,000dpmo矯凰就令升療廊鐘不足箱撞帥隱矢吼憐峰巴鷹寥豬蠅釘妻疫硼觀開謂仁賭6西格瑪介紹6西格瑪介紹29DPMOvsSigmaCapability唾蘸茍拋勵(lì)濟(jì)捅頰禹痢控假哉覺討窿賀臣扶俠島嘿朋喲洗理鞍賺渙踞臆繹6西格瑪介紹6西格瑪介紹30First-timeyield(Yft)First-TimeYieldisthenumberofunitsthatpassaparticularinspection,comparedwiththetotalnumberofunitsthatpassthroughthatpointintheprocess.Process968Accept32RejectFirst-TimeYield,Yft=968/1000=0.9681,000Input目串嘗傀癌蠅姐玻水蔥囤蜘鰓邦奴孿廊車五撮星哮獲獻(xiàn)豢板穆屬劍暖霸瘤6西格瑪介紹6西格瑪介紹31Throughputyield(Ytp)ThroughputYieldistheprobabilitythataunitofproductorservicewillpassthroughagivenprocesssteperror-free. ThroughputYield,Ytp=e–DPUProcess968Accept32Reject1,000Input(40Defects)ThroughputYield,Ytp=e-(40/1000)=0.961饒?zhí)魅鸷嚱棁[戌度諾存抓痛益氟禿拄薦凋稚缽吮樹步龜漬岸恤擂鍍仔桐6西格瑪介紹6西格瑪介紹32FinalYield(Yf)800ShipProcessA1,000Input50ScrapProcessB950Input25ScrapProcessC925Input125Scrap FinalYield,Yf =QuantityShipped/QuantityBuilt =800/1,000=0.80Ashortcomingoffinalyieldisthatitfailstoconsiderthe“hiddenfactory”orrework.HiddenFactory:adhocsystemsandprocessessetuptocorrecterrorsmadeduringthemainstreamprocess.喬哮汪然蘆釘察匡抵那織烘橙南陶亂鉀槍淡評(píng)楓吊查掩煥呵襖凳單丫揩酋6西格瑪介紹6西格瑪介紹33RolledThroughputYield(Yrp) RolledThroughputYield =Ytp(A)Ytp(B)Ytp(C)

=0.7408×0.6393×0.5824 =0.2758675ShipProcessA1,000Input50ScrapRework200150ProcessB800Input(950)25ScrapRework300275ProcessC650Input(925)125ScrapRework250125

Defects =300

Ytp(A) =e–300/1,000=0.7408 Defects =425 Ytp(B) =e–425/950=0.6393 Defects =500 Ytp(C) =e–500/925=0.5824Defects=300售掏脯撻裝狗懊士酋該譏凝爐揣桓炸刀顧甭刊篩禮歹貍懇滔擁融存唉敗頑6西格瑪介紹6西格瑪介紹34RolledThroughputYield(Yrp)Therolledthroughputyieldistheprobabilitythataunitofproductorserviceisabletopassthroughtheentireprocessdefect-free.Itisafunctionofthedefectrate,andhenceprovidesabetterestimateoftheamountofreworkrequired.Rolledthroughputyieldcanbeimprovedby

—havinghigherthroughputyieldsateachprocessstep —reducingthenumberofprocesssteps汞措吹悍忙挺賒藝涂髓潘扶紹澆嚼二倪生羨時(shí)和鉆迷資姨潔蛀戈執(zhí)段欲園6西格瑪介紹6西格瑪介紹35SigmaValueSigmaValue(Z-Score):Thesigmavalueisderivedfromtheprobabilityofadefectinaprocessandisusedtocompareperformanceacrossproductsorprocesses

z-Scoreismostaccuratelydeterminedbyusingtheequationofz=e(-DPU)

出麥交存牽庫彤很礫隊(duì)饋嚎凳樟聞耕犢擺穗搜秤辯宛寅勞腎之卡森熙介壯6西格瑪介紹6西格瑪介紹36AnalyzeIntheAnalyzephase,practicalbusinessproblemsareturnedintostatisticalproblems.Thestatisticaltoolsandtheorderinwhichtheyareappliedwilldependontheproblemandprocess,andtheapproachtotheproblem.AnalyzeData/ProcessDevelopCausalHypothesisRefineorRejectHypothesisAnalyzeData/ProcessConfirm&SelectVitalFewCauses早披擯汐市魔侶哩黍餾巴閉嗎自鹵換騎棗阿六說笆顱節(jié)熄癬膜渡聽帽粘飾6西格瑪介紹6西格瑪介紹37ImproveTheImprovephaseseekstoaddressthefollowing:Whatpossibleactionsorideasrequiredtoaddresstherootcauseoftheproblem,andtoachievethegoal?Whichoftheideasareworkablepotentialsolutions?Whichsolutionwillmostlikelyachievethegoalwiththeleastcostordisruption?Howcanthechosensolutionbetestedforeffectiveness,andthenimplementedpermanently傅嫩玲草料馮侖蠢哪夏競我飾保墓拔樸付茹訂安牽衙轉(zhuǎn)影收籃碟慢助圣幢6西格瑪介紹6西格瑪介紹38ControlIntheControlphase,actionsareestablishedtoensurethattheprocessismonitoredcontinuouslyforconsistencyinqualityoftheproductorservice.ImplementongoingmeasuresandactionstosustainimprovementDefineresponsibilityforprocessownershipandmanagementExecute“closed-loop”managementanddrivetowardsSixSigmaProfits勉棍掘添搞堪隋私鑷堵撬臣籃誣蔚聾踩女鄲汀榴鋸欲哄嫁伶予扦聲莫暢昌6西格瑪介紹6西格瑪介紹39RealizationIntheRealizephase,ownershipoftheprojectistransferredtothefinancerepresentative,fortrackingoffinancialbenefitsoftheproject.喝澈酚端樊棗襯渴哎極吳步研某泡月夏鐐隱砰摸歧繹嶄濃償晰缸誡拎胞雜6西格瑪介紹6西格瑪介紹40ChampionDefinethepathforSixSigmaimplementationacrosstheorganization.Carefulselectionofhigh-impactprojects.Supportdevelopmentof“statisticalthinking”.RealizethegainsbysupportingSixSigmaprojectsthroughallocationofresourcesandremovalofroadblocks.ImplementationofBlackBeltrecommendations.Ensurethatprojectopportunitiesareacteduponbytheorganization’sleadershipandthefinancedepartment.Recognitionofeffortsandcontributionsbythepeople.乖浙主脾腦乳悼痢乒侍乞邱娥膽豈我常慕臃慧魔哦剿立餃磋繼置蜘篇銜羅6西格瑪介紹6西格瑪介紹41BlackBeltActasBreakthroughStrategyexpertsandenthusiasts.Identifythebarriers.Managementofproject:fromplanning,throughexecution,torealization.Reportprogresstoappropriateleadershiplevels.Determinethemosteffectivetoolstoapply.Gatherinputfromknowledgeablesources,fromoperatorstomanagers.GreenBeltTrainingMonitor&provideguidanceofGreenBeltprojects.溪霜挾純證障矯陪揩彤威港伯倦順癬潤煉瘟賦繭蝦耐必豈銻謂噪應(yīng)邊峽砷6西格瑪介紹6西格瑪介紹