Chapter 5 Continuous Process Improvement

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Presentation transcript:

Chapter 5 Continuous Process Improvement Create a system for constant and continuous improvement

Understand the Process: Variations are Major Enemies Detecting mode (heavy dependence on inspection/testing/control): Fire fighting is not effective Preventive mode (emphasis on “do it right the first time and all the time): Use FEEDBACK to take corrective actions so that the process can be continuously improved.

Process Model

Process Improvement Strategy: Finding Cost Effective Solution Control existing process: i.e., statistical process control (SPC) Optimize the process: i.e., design of experiment (DOE) Change the system: hardware, software and brainware New system: machine, human, materials, method

PDSA Cycle: Embedded in the Continuing System Plan Do Study Act Plan again …

Problem Solving: A Continuous Effort Identify problems as an opportunity Analyze the problem: to find root causes Develop optimal and cost effective solutions Implement changes: system wide Study the results: worked or not? Need adjustment? Standardize solution: Keep problems from reoccurring.

Six Sigma: Aim High Specification Limit Defective Rate +/- 3 sigma 0.27% (2700 ppm) +/- 4 sigma 63 ppm +/- 6 sigma 0.002 ppm (3.4 ppm if process is not centered)