1. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt1020151207_v001_msamc_courseware_quality_ppt10 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License Multi-State Advanced Manufacturing Consortium US DOL SPONSORED TAACCCT GRANT: TC23767 RELEASE DATE12/7/2015 VERSIONv 001 PAGE1 of 15 PRIMARY DEVELOPER – Janaina Gasparelo, Henry Ford College I NTEGRATED Q UALITY S ESSION 10 P ROFESSOR J ANAINA G ASPARELO H ENRY F ORD C OLLEGE J ANUARY, 2015 US D EPARTMENT OF L ABOR M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM

2. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt1020151207_v001_msamc_courseware_quality_ppt10 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License What is Six Sigma? Is 99% Quality Good Enough? Six Sigma Quality But is Six Sigma Realistic? Six Sigma Improvement Methods DMAIC vs. DMADV Six Sigma DMAIC Process Six Sigma DMADV Process AGENDA

3. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt1020151207_v001_msamc_courseware_quality_ppt10 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License A goal of near perfection in meeting customer requirements A sweeping culture change effort to position a company for greater customer satisfaction, profitability and competitiveness A comprehensive and flexible system for achieving, sustaining and maximizing business success; uniquely driven by close understanding of customer needs, disciplined use of facts, data, and statistical analysis, and diligent attention to managing, improving and reinventing business processes (Source: The Six Sigma Way by Pande, Neuman and Cavanagh) WHAT IS SIX SIGMA?

4. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt1020151207_v001_msamc_courseware_quality_ppt10 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License 22,000 checks will be deducted from the wrong bank accounts in the next 60 minutes. 20,000 incorrect drug prescriptions will be written in the next 12 months. 12 babies will be given to the wrong parents each day. IS 99% QUALITY GOOD ENOUGH?

5. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt1020151207_v001_msamc_courseware_quality_ppt10 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License The objective of Six Sigma quality is 3.4 defects per million opportunities! SIX SIGMA QUALITY

6. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt1020151207_v001_msamc_courseware_quality_ppt10 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BUT IS SIX SIGMA REALISTIC? · 10 1 100 1K 10K 100K 765432 (66810 ppm) IRS – Tax Advice (phone-in) Best in Class (3.4 ppm) Domestic Airline Flight Fatality Rate (0.43 ppm) · (233 ppm) Average Company Purchased Material Lot Reject Rate Air Line Baggage Handling Wire Transfers Journal Vouchers Order Write-up Payroll Processing Doctor Prescription Writing Restaurant Bills · · · · · · · Defects Per Million Opportunities (DPMO) SIGMA

7. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt1020151207_v001_msamc_courseware_quality_ppt10 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License SIX SIGMA IMPROVEMENT METHODS: DMAIC VS. DMADV Define Measure Analyze Design Validate Improve Control Continuous ImprovementReengineering

8. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt1020151207_v001_msamc_courseware_quality_ppt10 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License SIX SIGMA IMPROVEMENT METHODS: DMAIC Define: Define who your customers are, and what their requirements are for your products and services – Their expectations. Define your team goals, project boundaries, what you will focus on and what you won’t. Define the process you are striving to improve by mapping the process.

9. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt1020151207_v001_msamc_courseware_quality_ppt10 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License SIX SIGMA IMPROVEMENT METHODS: DMAIC Measure: Eliminate guesswork and assumptions about what customers need and expect and how well processes are working. Collect data from many sources to determine speed in responding to customer requests, defect types and how frequently they occur, client feedback on how processes fit their needs, how clients rate us over time, etc. The data collection may suggest Charter revision.

10. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt1020151207_v001_msamc_courseware_quality_ppt10 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License SIX SIGMA IMPROVEMENT METHODS: DMAIC Analyze: Grounded in the context of the customer and competitive environment, analyze is used to organize data and look for process problems and opportunities. This step helps to identify gaps between current and goal performance, prioritize opportunities to improve, identify sources of variation and root causes of problems in the process.

11. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt1020151207_v001_msamc_courseware_quality_ppt10 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License SIX SIGMA IMPROVEMENT METHODS: DMAIC Improve: Generate both obvious and creative solutions to fix and prevent problems. Finding creative solutions by correcting root causes requires innovation, technology and discipline.

12. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt1020151207_v001_msamc_courseware_quality_ppt10 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License SIX SIGMA IMPROVEMENT METHODS: DMAIC Control: Insure that the process improvements, once implemented, will “hold the gains” rather than revert to the same problems again. Various control tools such as statistical process control can be used. Other tools such as procedure documentation helps institutionalize the improvement.

13. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt1020151207_v001_msamc_courseware_quality_ppt10 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License SIX SIGMA IMPROVEMENT METHODS: DMADV Design: Develop detailed design for new process. Determine and evaluate enabling elements. Create control and testing plan for new design. Use tools such as simulation, benchmarking, DOE, Quality Function Deployment (QFD), FMECA analysis, and cost/benefit analysis.

14. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt1020151207_v001_msamc_courseware_quality_ppt10 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License SIX SIGMA IMPROVEMENT METHODS: DMADV Validate: Test detailed design with a pilot implementation. If successful, develop and execute a full-scale implementation. Tools in this step include: planning tools, flowcharts/other process management techniques, and work documentation.

15. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt1020151207_v001_msamc_courseware_quality_ppt10 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License Multi-State Advanced Manufacturing Consortium US DOL SPONSORED TAACCCT GRANT: TC23767 RELEASE DATE12/7/2015 VERSIONv 001 PAGE15 of 15 PRIMARY DEVELOPER – Janaina Gasparelo, Henry Ford College SAFETY DISCLAIMER: M-SAMC educational resources are in no way meant to be a substitute for occupational safety and health standards. No guarantee is made to resource thoroughness, statutory or regulatory compliance, and related media may depict situations that are not in compliance with OSHA and other safety requirements. It is the responsibility of educators/employers and their students/employees, or anybody using our resources, to comply fully with all pertinent OSHA, and any other, rules and regulations in any jurisdiction in which they learn/work. M-SAMC will not be liable for any damages or other claims and demands arising out of the use of these educational resources. By using these resources, the user releases the Multi-State Advanced Manufacturing Consortium and participating educational institutions and their respective Boards, individual trustees, employees, contractors, and sub-contractors from any liability for injuries resulting from the use of the educational resources. DOL DISCLAIMER: This product was funded by a grant awarded by the U.S. Department of Labor’s Employment and Training Administration. The product was created by the grantee and does not necessarily reflect the official position of the U.S. Department of Labor. The Department of Labor makes no guarantees, warranties, or assurances of any kind, express or implied, with respect to such information, including any information on linked sites and including, but not limited to, accuracy of the information or its completeness, timeliness, usefulness, adequacy, continued availability, or ownership. RELEVANCY REMINDER: M-SAMC resources reflect a shared understanding of grant partners at the time of development. In keeping with our industry and college partner requirements, our products are continuously improved. Updated versions of our work can be found here: http://www.msamc.org/resources.html.http://www.msamc.org/resources.html