1. Life Cycle Engineering Associates
“Six-Sigma [6s] for Managers” The Concept & Method of Six-Sigma prepared for American Society of Quality Baltimore Section Breakfast meeting
LCEA
Life
Cycle
Engineering Associates
Presented by:
John Weisz CQE, CRE
18 March 2004
my docs\6sigma for ASQ Managers.ppt
12/6/2018

2. What is “6-s?” A statistical measurement: a business strategy ...
“sigma” = “s” = one standard deviation [statistic]
measures the degree to which ANY business process deviates from its goal or standard
[see next page]
a business strategy ...
that can lead to breakthrough improvements in profitability and quantum improvements in quality
that can provide decisive competitive edge as quality improves and costs go down
a philosophy …
the context for how we work & compete in the marketplace
working “smarter, not harder”
preventive, pro-active approach to reducing errors/defects
focused on understanding and reducing variation
my docs\6sigma for ASQ Managers.ppt
12/6/2018

3. “Six-Sigma” Illustrated
Average or Mean
of Distribution 2
[~95% of distribution
is defect free] 3 5
[~99.7%]
[~99.99%]
[~99.987%]
[~ %] 4 6
Example:
Imagine manually typing a book...
3  = 1 misspelled word for every page of text*
6  = 1 misspelled word for every 1,000 pages*
This ‘tail’ of the distribution represents the # of defects[outside of the distribution ‘limits’] for a certain level of “s” process capability.
In this case, for 6- quality, there are less than 1.7 defects per million opportunities to produce a defect [multiply by 2 to take both ‘tails’ into account]
* = assumes average of 334 words/page
my docs\6sigma for ASQ Managers.ppt
12/6/2018

4. The Benefits of Quality in“Sigma” A Real-World Manufacturing Example
Mean
2.05
[~96% of distribution] 3
[~99.7%]
3.5
[~99.9%]
Cost Improvement Due to In-House CQI Program Costs Before ]: $115k per month
PHASE I [to 3s Quality]
Cost Savings: ~ $60K in quality costs per month
Cost to Implement:
Non-recurring = $120K
Recurring = $5K per month
ROI: 450% in first year!
PHASE II [to 3.5s Quality]
Cost Savings: ~ $30K in per month
Cost to Implement:
Non-recurring = $45K
Recurring = $3K per month
ROI: 520% in first year!
my docs\6sigma for ASQ Managers.ppt
12/6/2018

5. Some Myths [& Truths] About 6-s
my docs\6sigma for ASQ Managers.ppt
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6. The Advantages of “Quantum Improvement” [see Jay Arthur’s Six-Sigma Simplified (LifeStar,2000)]
my docs\6sigma for ASQ Managers.ppt
12/6/2018

7. 6-s Basic & Advanced Tools1
Line Chart 1
Life Cycle Cost Analysis 2
Process Failure Mode & Effects Analysis
[P-FMEA] and/or Design FMECA 2
Pareto Graph 3
Statistical Design of Experiments [SDE] 4
Quality Function Deployment [QFD] 3
Fishbone 5
KANO Map
[Ishakawa] 6
Value Stream Mapping 4
Flow Chart 7
Customer Satisfaction Measurement &
Management system [CSSM] 8
Countermeasures Matrix 9
Force Field Analysis 5
Control Chart 10
Action Plan 11
Capability Analysis
my docs\6sigma for ASQ Managers.ppt
12/6/2018

8. Prerequisites for Sustained Process Improvement
Define the process thru flowcharts, Value Stream maps, Process Failure Modes & Effects Analysis
Assure process stability thru Statistical Process Control [consistency & “precision”]
Assure process capability thru 6-Sigma methods & “capability analysis” [reflects “accuracy” in process, meeting Customer needs, minimum waste or risk to producer or consumer]
my docs\6sigma for ASQ Managers.ppt
12/6/2018

9. Design for Six Sigma [DFSS] The Underlying Truth behind 6-s
FACT!
“You can’t achieve 6-s by applying only 6-s tools & methods”
[The Principle of “Accrued Error”:]
Start with small error [i.e., wrong requirement]
compound it in next phase [right design for wrong requirement]
worse in next phase [ good test for right design but doesn’t prove the requirement is met]
during “Operations & Maintenance” phase ... [you have to jury rig fixes]
my docs\6sigma for ASQ Managers.ppt
12/6/2018

10. DFSS in Context
my docs\6sigma for ASQ Managers.ppt
12/6/2018

11. TRIZ: Background TRIZ = (Russian) =Theory of Inventive Problem-Solving
Continuous & natural outgrowth of Quality ‘revival of the 1980’s until today
QFD, 6s & DFSS tell us what to solve but not how to solve problems
Genrich S. Altschuller is the “Father of TRIZ”
Soviet inventor & patent expert
screened over 200k patents & found only 90% were somewhat inventive
categorized solutions by problem-solving process, instead of by industry or other attributes
my docs\6sigma for ASQ Managers.ppt
12/6/2018

12. Concept of TRIZ Goal is to overcome “psycho-inertia”
natural tendency to look for solutions only from one’s own experience and profession
Other people’s problems A
Analogous Solution Sets
Prism of TRIZ B C
A B C D E F G H I J K L D E
My problem F
Previous problems efficiently & effectively resolved
Optimal Solution for my problem
DFSS requires ”innovative problem solving” [=“TRIZ”]
my docs\6sigma for ASQ Managers.ppt
12/6/2018

13. Conclusions about “6-s”
Each “sigma” step closer to “6s” results in…
lower cost [due to shorter cycle times, less non-value-added steps and less rework]
shorter time to market [less delays in development of new products/services/software]
more competitive products [less defects; meets Customer needs]
Traditional 6-s is not the only way. Faster implementation at lower costs is possible using “Immediate Return 6-Sigma”[IR6S]
IR6S tools are easy! In addition to faster ROI…
traditional 6-s tools are truly absorbed & embraced “a bite at a time” by employees
setting the stage for strategic employment of traditional 6-s
after Exec. Management & employees are convinced of its utility & encouraged
Can’t reach 6s without DFSS [or TRIZ ?]
The cost to start is lower than you think…
…the “price” not to …is unthinkable!
my docs\6sigma for ASQ Managers.ppt
12/6/2018