Usage of Six Sigma Six Sigma is not only a learning tool. Process improvement refers to a strategy of finding solutions to eliminate root causes of performance problems. --Project --Manufacture

Actuality of Chinese Manufacture Defects in Manufacture Process Assembly Line Defects Sourcing Defects Random Defects Etc. Defects in Supply Chain Transportation Inefficiency Information Blocking

Defects and Six Sigma Levels Defect: anything that does not meet customer requirements. e. g: a rude reception clerk is providing defective service. By measuring customer requirements. By calculating defective opportunities: DPMO

Critical ingredients 1.Continuous focus on customer 2.Data and Fact-driven * 3.Process focus *get rid of unfounded assumptions. Asking question: what data I need?

Why data is important? The company is growing more complex and the need for information on how things are operating is becoming more critical. The more complex of constraints the process have, the more difficult to identify problems by experiences. Concise and exact way to evaluate process: DATA

How to implement Six Sigma Project in Chinese Manufacture? The initiative of Six Sigma Project Requirements of Quality by Vendor The list of Six Sigma projects to fix defects will be given by Vendor. Supplier: Chinese manufacturer Methodology Vendor will identify defect in manufacturing supply chain using SIPOC model.

Identifying and Documenting the Process SIPOC “ Big Picture ” perspective, additional detail can be added

SIPOC Focus on the step (s) where the suspected causes of the symptoms in the Problem Statement Process: heading, threading, heat treatment, decarburization …

Define Define Measure Analyze Improve Control Customer requirements: quality of product keep a consistent level. e. g: bolts; packaging labels Chinese manufacturer should guarantee their products sustain that level e. g: take defect rate of 1,100(3 sigma) to 100(6 sigma) level.

Case A: Our goal: Find out weaknesses which hidden in the process then improve it to meet the tolerance requirements. Two categories have to be identified: Load tests of bolts Tensile strength requirements

Define Measure Define Measure Analyze Improve Control Studying manufacturing process capability and quality characteristics Step 1: Collect data some variations? Step 2: Make plot graph and diagram increase the power of data analysis efforts. (EXCEL;MINITAB)

X-Bar chart for subgroup1,2

Process capability chart Variation in process. It presents some defective samples below the lowest specification

Qualified bolts (all of samples)

Analyze Define Measure Analyze Improve Control Recall the SIPOC diagram, identify areas where the process steps, responsibilities, or outcomes are unclear or produce no- value-added work. Pay attention on the first several procedures or work stations. (Bull-whip effect)

Variables in Process Z Value: Crossing Assembly Line and Transportation Process Information and Product Flow

Data/Material flow chart

Final inspection data Find data to analysis and calculate.

We could figure out the defects in every process, for example, in heat treatment. Have a hypothesis (Brainstorm), even their theories are wrong, have to be open to the possibility which supported by data. Hint: document all the case in process using table, graph, statistic software (MINITAB) … Improve Define Measure Analyze Improve Control

Manufacturer transition diagram. Supply chain (Markov Model)

Supply Chain Six Sigma Improvement Order/Information Flow and Product Flow Markovian queue--combine information and product flow The customer, vendor, Chinese manufacturer and raw material supplier are in the chain where the external environment is a continuous time Markovian chain using data communication networks by order or product flow

Improve Define Measure Analyze Improve Control Profit Margins Continual Six Sigma improvement to streamline and cut the cost out of a supply chain.

Control Define Measure Analyze Improve Control Go back to control chart (X-chart, R-chart ) and review it. Control limit recalculation. Recording all the defective opportunity. Keep using control chart within whole process.

Conclusion Six Sigma in manufacture process influences the decision making The first step: Reducing DPMO based on the actual circumstances by using statistic knowledge Factors and Results The Second Step: The Markovian model used in Supply Chain