1 Prof. Indrajit Mukherjee, School of Management, IIT Bombay Bill Smith’s findings…. Bill Smith’s paper concluded that if product was found defective and corrected in the process, some defects are likely to be detected by customer in early usage. Early Life Failures Corrections and reworks in process

2 Prof. Indrajit Mukherjee, School of Management, IIT Bombay Processes tend to shift increasing the chances of defects. The six sigma metric:

3 Prof. Indrajit Mukherjee, School of Management, IIT Bombay

4 ATTACKING PROBLEMS: PRE-PROCESS EXCELLENCE PRACTICAL PROBLEM PRACTICAL SOLUTION NEXT PROBLEM In some cases, effective… But can result in perceptions of fire fighting and in recurring problems.

5 Prof. Indrajit Mukherjee, School of Management, IIT Bombay PRACTICAL PROBLEM STATISTICAL SOLUTION STATISTICAL PROBLEM PRACTICAL SOLUTION Define Control Innovative Improvement Analyze Measure The DMAI2C/Six Sigma Way to Attack Problems

6 Prof. Indrajit Mukherjee, School of Management, IIT Bombay Define Measure Analyze Improve Control The Six Sigma Funnel to reduce Process Variation All possible Xs Vital Few ‘x’s

7 Prof. Indrajit Mukherjee, School of Management, IIT Bombay Application Strategy Define project scope Validate measurement systems Establish initial capability for Ys Process exploration of all potential Xs  Characterize the response and analyze the raw data  Bimodal? Skewed? Is the problem with mu or sigma?  Use graphical analysis, regression, multivariate analysis, hypothesis testing, and basic statistical tools to identify the likely families of variability  Identify the likely Xs  Use the design of experiments to find the critical few Xs  Move the distribution (shift mu)  Shrink the spread (decrease sigma)  Confirm the results  Mistake-proof the process  Tolerance the process  Measure the final capability  Place appropriate process controls on the critical Xs  Document the effort and results Control Improve Analyze Define Measure

8 Prof. Indrajit Mukherjee, School of Management, IIT Bombay Application Strategy Phase 1: Product Measurement Operation Verify

9 Prof. Indrajit Mukherjee, School of Management, IIT Bombay Application Strategy Phase 2: Product Performance Analysis All possible Xs Probable Xs

10 Prof. Indrajit Mukherjee, School of Management, IIT Bombay EMC Application Strategy Phase 4: Process Control

11 Prof. Indrajit Mukherjee, School of Management, IIT Bombay The Process Six Sigma Roadmap Define Measure Analyze Improve Control Charter, Teaming FMEA, Process Map, C&E MSA Cpk Anova, Regression, Multivariate analysis Design of Experiments, Response Surface Optimization, Poka Yoke SPC, Control Plans All possible Xs Few ‘x’s

12 Prof. Indrajit Mukherjee, School of Management, IIT Bombay Define Measure Control Improve Analyze Value Stream Mapping Product Families Product flow Analysis Workplace Design Material Replenishment Set-up Reduction Standard Work 5S Implementation Performance Metrics SIPOC Detailed Process Map Failure Modes Analysis FMEA Measurement System MSA T-Test, Chi Square, ANOVA, COV Design of Experiments DOE Control Strategies Regression Analysis Mistake Proofing

13 Prof. Indrajit Mukherjee, School of Management, IIT Bombay Six Sigma Performance Metrics Process capability Cp Cpk Pp,Ppk First Time Yield Defects per Million opportunities, DPMO Parts per million, ppm IndividualProduct

14 Prof. Indrajit Mukherjee, School of Management, IIT Bombay Rolled Throughput Yield Example The pedal sub-assembly process is outlined below. We have identified the DPU associated with each process step. Select R and L part #s from bin location DPU = 0 02 Hand- tighten L pedal DPU = 0 01 Hand- tighten R pedal DPU = 0 01 Torque L pedal to 5 ft Lbs DPU = 0 03 Torque R pedal to 5 ft Lbs DPU = 0.03 OR RTY=0.98*0.99*0.99*0.97*0.97 =90% Process stepDPU Actual Yield Select part0.0298% Hand tighten L0.0199% Hand tighten R0.0199% Torque L0.0397% Torque R0.0397% Total0.1

15 Prof. Indrajit Mukherjee, School of Management, IIT Bombay Assembly and Packaging BluingFittingTightening Packaging Leak Test QA Release Suppliers: valve manufacturers (external & internal) body manufacturers (external & internal) planing shop packaging materials Suppliers turning shop production planning Inputs: valves bodies packaging Materials miscellaneous consumables production schedules Outputs: assembled and packaged valves production materials usage reports leak test report Customers: warehouse (internal) end users(external) production scheduling purchasing QA Start boundary: Run initiated per production schedule Example Process Map for Assembly and Packaging Process End boundary: Packages released for transfer to warehouse

16 Prof. Indrajit Mukherjee, School of Management, IIT Bombay Green Belts... ORGANIZATION FOR SIX SIGMA IMPLEMENTATION CEO Corporate Quality Council (Group of Champions) Black Belts (Facilitators) (Corporation)

17 Prof. Indrajit Mukherjee, School of Management, IIT Bombay Six Sigma Steering Committee CEO Quality Manufacturing Finance H.R. Service Marketing Master Black Belt

18 Prof. Indrajit Mukherjee, School of Management, IIT Bombay Design for Six Sigma (DFSS) Taking variability reduction upstream from manufacturing (or operational six sigma) into product design and development Every design decision is a business decision Customer CTQ’s System parameters Subsystem parameters Component parameters Part characteristics

19 Prof. Indrajit Mukherjee, School of Management, IIT Bombay Design Predictive Quality into products DFSS Robust Eliminate Waste, Improve Cycle time Lean Lead- Time Eliminate Defects, Reduce variability Six sigma/ DMAIC* Capable Design for six-sigma Lean Variation Reduction The “I” in DMAIC may become DFSS Six-Sigma/DMAIC, lean, and DFSS: How they fit together