Ch21 Six Sigma

8/18/2019 Ch21 Six Sigma

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Work Systems and the Methods, Measurement, and Management of Work by Mikell P. Groover, ISBN 0-13-140650-7.©2007 Pearso !"#$a%io , I $., &''er Sa""le (iver, N). *ll ri+ %s reserve".

Si Si+ a a "

Se$%io s/1. vervie a " S%a%is%i$al Basis o Si

Si+ a2. e Si Si+ a M*I Pro$e"#re3. % er #ali%y Pro+ra s

a'%er 21

% er #ali%y Pro+ra s


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a% is #ali%y8

9% e "e+ree o e $elle $e i$ a % i +'ossesses:9$o or a $e %o re;#ire e %s:9;#ali%y is $#s%o er sa%is a$%io :9% e %o%ali%y o ea%#res a " $ ara$%eris%i$s o'ro"#$% or servi$e % a% bear o i%s abili%y %osa%is y +ive ee"s:


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!i+ % i e sio s o #ali%y

1. Per or a $e > o'era%i + $ ara$%eris%i$s2. ?ea%#res > o'%io s % a% "is%i +#is 'ro"#$%3. *es% e%i$ a''eal > s%yle, a''eara $e4. o or a $e - ork a s i'5. (eliabili%y > al ays available or % e

$#s%o er 6. #rabili%y > las%s a lo + %i e7. Servi$eabili%y > o easy %o ai %ai@. Per$eive" ;#ali%y > bra " re$o+ i%io


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vervie o Si Si+ a

Si Si+ a A a ;#ali%y- o$#se" 'ro+ra % a% #%ili esorker %ea s %o a$$o 'lis 'roCe$%s ai e" a%

i 'rovi + a or+a i a%io Ds o'era%io al'er or a $e

S%ar%e" a% Mo%orola or' i 1E@0sS%ar%e" by Mikel Farry a% Mo%orola i 1E70s! $o#ra+e" by ! (ober% GalviMo%orola i s Mal$ol Bal"ri+e * ar", 1E@@

S#bse;#e %ly a"o'%e" by o% er $o 'a ies,i $l#"i + G!

G! $lai s savi +s i billio s


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Ge eral Goals o Si Si+ a

Be%%er $#s%o er sa%is a$%ioFi+ ;#ali%y 'ro"#$%s a " servi$es(e"#$e" "e e$%sI 'rove" 'ro$ess $a'abili%y % ro#+ re"#$%ioi 'ro$ess varia%io s

o %i #o#s i 'rove e %os% re"#$%io % ro#+ ore e e$%ive a "

e i$ie % 'ro$esses


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#ali%y base" o Nor al is%rib#%io

ra"i%io al e%ri$ or +oo" 'ro$ess ;#ali%y is H3 σ I $l#"es EE.73 o 'o'#la%io

e e$% ra%e A 2700 "e e$%s 'er illioSi Si+ a e%ri$ is H6 σ

I % e S%a "ar" Nor al %ables/I $l#"es EE.EEEEEE@ o 'o'#la%io

e e$% ra%e A 0.002 "e e$%s 'er illio


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± 3σ i % e Nor al is%rib#%io

Nor al "is%rib#%io o 'ro$ess o#%'#% variable,s o i + % e± 3σ li i%s


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± 6σ i % e Nor al is%rib#%io


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Si+ a Jal#e a " e e$% (a%e i % eSi Si+ a Pro+ra

Pro$ess si+ a e e$% ra%e Kiel"1σ 6E1,462 ' 30.E2σ 30@,53@ ' 6E.13σ 66,@07 ' E3.34σ 6,210 ' EE.45σ 233 ' EE.E@6σ 3.4 ' EE.EEE66


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y % e i ere $e8

e Mo%orola e +i eers "evise" Si Si+ a,% ey $o si"ere" 'ro$esses % a% o'era%e over% e lo + r#

ver % e lo + r# , 'ro$ess ea s %e " %o s i %

o $o 'e sa%e, Mo%orola sele$%e" %o #se 1.5 σ as % e a+ i%#"e o % e s i %

#s, 6 si+ a really ea s 4.5 si+ a


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Nor al is%rib#%io S i % by 1.5σ


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?ive S%e's i Si Si+ a

M*I i 'le e % $o %rol over % e

e or i 'rove" 'ro$ess


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1. e i e

P ases o % e "e i e s%e'1. r+a i e % e 'roCe$% %ea2. Provi"e i% i% a $ ar%er


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e ProCe$% ea

Bla$k bel% - %ea lea"er i a Si Si+ a 'roCe$%Possesses "e%aile" %rai i + i Si Si+ a

*sso$ia%e" i% % e 'ro$ess o i %eres%Gree bel% - %ea e ber o as so e%rai i + i Si Si+ aMas%er bla$k bel% - $o s#l%a % a " e %or orbla$k bel%s

a 'io - e ber o a a+e e %er o % e 'ro$ess % a% ee"s

i 'rove e %


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e ar%er

B#si ess $ase > y % e 'roCe$% s o#l" bea$$o 'lis e"Proble s%a%e e %Goals a " obCe$%ivesMiles%o es > eas#res o 'ro+ress(oles a " res'o sibili%ies o %ea e bers


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e i e


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2. Meas#re

P ases o % e eas#re s%e'/1. rea%e "a%a $olle$%io 'la2. I 'le e % % e 'la


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rea%e a%a olle$%io Pla

ere eas#re e %s s o#l" o$$#r/I '#% eas#res


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I 'le e % a%a olle$%io Pla

olle$% % e "a%a *"C#s% e %s i 'la so e%i es re;#ire""#e %o

& a %i$i'a%e" o$$#rre $esI"e %i i$a%io o i 'or%a % variables % a%

ere 'revio#sly overlooke"ea e bers s o#l" be i volve" i% % e

"a%a $olle$%ioe %ask s o#l" o% be "ele+a%e"


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Meas#re #rre % Si+ a Level

Provi"es s%ar%i + 'oi % or i 'rove e %s *llo s be ore a " a %er $o 'ariso s

o "e%er i e si+ a level, irs% $o '#%e "e e$%s'er illio


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Meas#res o e e$%s 'er Millio

1. e e$%s 'er illio o''or%# i%ies

2. e e$%s 'er illio

3. e e$%ive # i%s 'er illio

ere $ d A # ber o "e e$%s, $ u A # ber o # i%s,$ o A # ber o o''or%# i%ies or a "e e$% 'er # i%,$ du A # ber o "e e$%ive # i%s

ou

d

$ $

$ ,,D%M& 0000001=

u

d

$ $

,,D%M 0000001=

u

du

$

$ ,,D'%M 0000001=


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Si+ a Jal#e a " e e$% (a%e i % eSi Si+ a Pro+ra

Pro$ess si+ a e e$% ra%e Kiel"1σ 6E1,462 ' 30.E2σ 30@,53@ ' 6E.13σ 66,@07 ' E3.34σ 6,210 ' EE.45σ 233 ' EE.E@6σ 3.4 ' EE.EEE66


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3. * alysis

P ases o % e a alysis s%e'/1. Basi$ "a%a a alysis2. Pro$ess a alysis3. (oo% $a#se a alysis


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Basi$ a%a * alysis

P#r'ose is %o 'rese % % e "a%a i a ay % a%le "s i%sel %o aki + i ere $es

&s#ally ea s +ra' i$al "is'laysis$re%e "a%a/ is%o+ra s, Pare%o $ ar%s,

'ie $ ar%s, "e e$% $o $e %ra%io "ia+ra so %i #o#s "a%a/ $ e$k s ee%s, s$a%%er

"ia+ra s *""i%io al %e$ i;#es/ a alysis o varia $e,

re+ressio a alysis, y'o% esis %es%i +


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ork Sys%e s a " % e Me% o"s, Meas#re e %, a " Ma a+e e % o orkby Mikell P. Groover, ISBN 0-13-140650-7.©2007 Pearso !"#$a%io , I $., &''er Sa""le (iver, N). *ll ri+ %s reserve".

defect concentration diagrams example


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Pro$ess * alysis

o $er e" i% /I %er're%i + res#l%s o basi$ "a%a a alysis

evelo'i + a ore "e%aile" 'i$%#re o % eay % e 'ro$ess o'era%es a " a% isro + i% i%

Pro$ess a's o "e%ails are #se" erey'i$al ;#es%io s i 'ro$ess a alysis/

a% are val#e-a""i + s%e's i 'ro$ess8a% are o -val#e-a""i + s%e's8i$ s%e's +e era%e "e e$%s a " errors8


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Jal#e-*""i + S%e's i Pro$ess

P ysi$al $ a +e i % e 'ro"#$% or servi$e#s%o er o % e s%e' $o si"ers i% i 'or%a %

I% is "o e $orre$%ly % e irs% %i e


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No -Jal#e-*""i + S%e's i Pro$ess

(e'ea%e" s%e'sProble "e%e$%e" by % e $#s%o er

elay % a% $a#ses ai%i + %i eI s'e$%io %o veri y $o 'le%io o orkPre'ara%io or se%#'Moves o % e 'ro"#$% or $#s%o er ro o e'la$e %o a o% er


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(oo% a#se * alysis

bCe$%ive is %o i"e %i y % e si+ i i$a % a$%o% a% a e$% 'ro$ess 'er or a $e

y A f < ( 1, ( 2, . . ., ( i , . . ( n=ere y A o#%'#% variable o i %eres%, a " ( 1,

( 2, . . ., ( i , . . ( n are i "e'e "e % variables i% e 'ro$ess


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P ases i (oo% a#se * alysis

Brai s%or y'o% eses abo#% % e 'ro$essrela%io s i's a " 'roble s

&se #l %ool/ $a#se-a "-e e$% "ia+ra(es#l% o brai s%or i +/ lis% o 'ossible

y'o% eses!li i a%e # likely y'o% esesJali"a%e % e re ai i + y'o% eses


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4. I 'rove

P ases i % e i 'rove s%e'/1. Ge era%e al%er a%ive i 'rove e %s2. * aly e a " 'riori%i e al%er a%ive

i 'rove e %s

3. I 'le e % i 'rove e %s


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Ge era%e *l%er a%ive I 'rove e %s

Sear$ or i 'rove e %s a " sol#%io s % a% ill/(e"#$e "e e$%sI $rease $#s%o er sa%is a$%ioI 'rove ;#ali%y o 'ro"#$% or servi$e(e"#$e varia%ioI $rease 'ro$ess e i$ie $y


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* aly e a " Priori%i e

Likely % a% % e lis% o i 'rove e %s is %oo lo + %i 'le e % all o % e

M#s% "is$ar" % ose al%er a%ives % a% are"ee e" i 'ra$%i$al

Priori%i e % e re ai i + al%er a%ivese$ i;#es/

Pro$ess a''i +?ail#re o"e a " e e$% a alysis


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?ail#re Mo"e a " ! e$% * alysis

Sys%e a%i$ %e$ i;#e %o i"e %i y 'o%e %ial ays ii$ a 'ro$ess or 'ro"#$% $a ail a "

assess risk a " severi%y o % e ail#re?a$%ors $o si"ere"/

1. Possible ail#re o"e - o $a i% ail82. $$#rre $e - o likely is ail#re %y'e83. Po%e %ial e e$%s - a% ill $#s%o er

e 'erie $e i ail#re o$$#rs84. Severi%y - ra +es ro 9 o e e$%: %o 9very

a ar"o#s i% o ar i +:5. e%e$%io - o "i i$#l% %o "e%e$% be ore

ail#re o$$#rs8


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Pare%o Priori%y I "e

Pare%o 'riori%y a%ri "e i e" as ollo s/

ere *


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ri%eria Ma%ri

ab#lar lis%i + o al%er a%ives a " % e $ri%eria byi$ % ey ill be eval#a%e"

ri%eria "ivi"e" i %o % o $a%e+ories/1. M#s% $ri%eria

2. esirable ea%#res *l%er a%ives % a% "o o% sa%is y % e #s%$ri%eria are eli i a%e"(e ai i + al%er a%ives are eval#a%e" #si + as$ori + s$ e e


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! a 'le/ ri%eria Ma%ri I "#s%rial (obo% a "i"a%es

Mo"el * Mo"el B Mo"el Mo"el M#s% ea%#res/

o %i #o#s 'a% $o %rol Si -a is robo% ar No%

alk% ro#+ 'ro+ra i + esirable ea%#res/

!ase o 'ro+ra i +


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5. o %rol

P#r'ose is %o ai %ai i 'rove" 'er or a $e% a% as a$ ieve" % ro#+ i 'le e %a%io o% e 'ro'ose" i 'rove e %s

*$%io s i % e $o %rol s%e'/

1. evelo' $o %rol 'la2. ra s er res'o sibili%y ba$k %o ori+i al

o er 3. isba " Si Si+ a %ea


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y is % e o %rol S%e' Ne$essary8

F# a resis%a $e %o $ a +eo or% i% 'revio#s e% o"

*bse $e o s%a "ar" o'era%i + 'ro$e"#res"e%aili + e e% o"

I a"e;#a%e o i%ori + o 'ro$ess 'er or a $eLa$k o a%%e %io by s#'ervisio


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evelo' o %rol Pla

o$# e % res#l%s o % e i 'rove e % 'roCe$%!s%ablis standard o erating ro edure


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?i al *$%io s

ra s er res'o sibili%y or 'ro$ess ba$k %oori+i al o er

Make s#re o er # "ers%a "s $o %rol 'laa " % a% i% ill be $o %i #o#sly i 'le e %e"

Si Si+ a %ea is "isba "e"Bla$k bel% is assi+ e" %o e %ea a " % e

e % 'roCe$%


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% er #ali%y Pro+ra s

ra"i%io al #ali%y o %rolS%a%is%i$al Pro$ess o %rol


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ra"i%io al #ali%y o %rol

?o$#s o i s'e$%io > "e%e$%i + 'oor ;#ali%ya " %aki + $orre$%ive a$%io %o eli i a%e i%

*%%e %io o sa 'li + a " s%a%is%i$al e% o"sPri $i'al %ools

o %rol $ ar%s *$$e'%a $e sa 'li +


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S%a%is%i$al Pro$ess o %rol

I volves % e #se o vario#s e% o"s %oeas#re a " a aly e a 'ro$ess

*''li$able i bo% a # a$%#ri + a " servi$eo'era%io s

bCe$%ives/I 'rove ;#ali%y o 'ro$ess o#%'#%(e"#$e 'ro$ess variabili%y a " a$ ieve'ro$ess s%abili%y

Solve 'ro$essi + 'roble s


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Seve ools i SP

1. Fis%o+ra s2. Pare%o $ ar%s3. e$k s ee%s4. e e$% $o $e %ra%io "ia+ra s5. S$a%%er "ia+ra s6. a#se a " e e$% "ia+ra s7. o %rol $ ar%s


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o%al #ali%y Ma a+e e %

Ma a+e e % a''roa$ % a% '#rs#es % ree aiobCe$%ives/1. *$ ievi + $#s%o er sa%is a$%io

I %er al a " e %er al $#s%o ers

I 'or%a $e o 'ro"#$% "esi+2. ! $o#ra+i + i volve e % o % e e %ire

ork or$e3. o %i #o#s i 'rove e %


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a+#$ i Me% o"s i !

(ob#s% "esi+esi+ 'ro"#$%s a " 'ro$esses i i$ % e# $%io a " 'er or a $e are rela%ively

i se si%ive %o varia%io s

a+#$ i loss # $%ioMos% %olera $es "e i e a ra +e o 'ara e%erval#es


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#ali%y ?# $%io e'loy e %

bCe$%ive is %o "esi+ 'ro"#$%s % a% ill sa%is y ore $ee" $#s%o er re;#ire e %s

? #ses a or al a " sys%e a%i$ 'ro$e"#re or"e i i + $#s%o er "esires a " re;#ire e %s, a "

i %er're%i + % e i %er s o 'ro"#$% ea%#res#s%o er re;#ire e %s are %ra$e" ba$k %o

'ro"#$% ea%#resPro"#$% ea%#res are %ra$e" ba$k %o

a # a$%#ri + re;#ire e %sMa # a$%#ri + re;#ire e %s are %ra$e" ba$k%o ;#ali%y 'ro$e"#res


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IS E000

* se% o i %er a%io al s%a "ar"s o ;#ali%y"evelo'e" by % e I %er a%io al r+a i a%io orS%a "ar"s


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IS E000

Ch21 Six Sigma

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