Six Sigma-Top Bosses

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    Excellence is doingExcellence is doing

    ordinary thingsordinary things

    extraordinary wellextraordinary well

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    Perfection is notPerfection is not

    attainable. But ifattainable. But if

    we chase perfectionwe chase perfection

    we can catchwe can catch

    excellence.excellence.

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    KAI ENCONSULTANTS

    Q

    Discovery of Bill SmithDiscovery of Bill Smith

    Number of repairs in factoryNumber of repairs in factory

    FieldFailures

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    KAI ENCONSULTANTS

    Q

    100 times100 times

    4 years

    Desire of CEO at MotorolaDesire of CEO at Motorola

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    C h i h t

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    KAI ENCONSULTANTS

    Q Comprehensive approach toComprehensive approach to

    excellenceexcellence

    Commitment/Sustainability

    Be

    nefits

    Business asBusiness as

    usualusual

    Rapid expenseRapid expensereductionreduction

    TraditionalTraditionalprojectproject

    managementmanagementDMAIC

    DFSSDFSS

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    KAI ENCONSULTANTS

    Q

    Facets of Six SigmaFacets of Six Sigma

    Facets ofFacets ofSix SigmaSix Sigma

    VisionVision To be known as best To be known as best

    companycompany

    GoalGoal Only 3.4 defects in Only 3.4 defects inmillion opportunitymillion opportunity

    MethodologyMethodology Disciplined Disciplined

    framework for problemframework for problem

    solvingsolving

    MetricMetric Something we Something wecalculate & measure tocalculate & measure to

    indicate level ofindicate level of

    process performanceprocess performance

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    KAI ENCONSULTANTS

    Q

    Typical functional processesTypical functional processes

    Product developmentProduct development

    Marketing/sales/customer servicesMarketing/sales/customer services

    Production planningProduction planning

    Quality and testingQuality and testing

    Technology supportTechnology support

    DistributionDistribution

    Billing/contractBilling/contract

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    Q U d t di i tiU d t di i ti

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    KAI ENCONSULTANTS

    Q

    0

    5

    10

    15

    20

    25

    2.267

    2.274

    2.281

    2.288

    2.295

    2.302

    2.309

    2.316

    2.323

    2.330

    Frequ

    enc

    Understanding process variationUnderstanding process variation

    - pattern of population- pattern of population

    Q

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    KAI ENCONSULTANTS

    Q

    Understanding process variationUnderstanding process variation

    -4 -3 -2 -1 0 1 2 3 4

    Process spread

    ProcessProcessmeanmean

    Process spread expressed as

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    Q

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    KAI ENCONSULTANTS

    Q

    Sigma Level of Quality - MathematicallySigma Level of Quality - Mathematically

    It is the distance of upper or lower

    specification limits from target

    measured in terms of standard

    deviation, .

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    Q

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    KAI ENCONSULTANTS

    Q

    Three Sigma process (Three Sigma process ( = 2/3)= 2/3)

    % with in specification = 99.73% with in specification = 99.73

    DPMO without shift = 2,700 =(0.27%)DPMO without shift = 2,700 =(0.27%)

    16 18 20 22 24 26 28

    LSLLSL USLUSL33 33

    Q

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    KAI ENCONSULTANTS

    Q

    Four Sigma process (Four Sigma process ( = 0.5)= 0.5)

    % with in specification = 99.9937% with in specification = 99.9937

    DPMO without shift = 63DPMO without shift = 63

    16 18 20 22 24 26 28

    LSLLSL USLUSL44 44

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    Q

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    KAI ENCONSULTANTS

    Q

    Six Sigma process (Six Sigma process ( = 0.333)= 0.333)

    % with in specification = 99.9999998% with in specification = 99.9999998

    DPMO without shift = 0.002DPMO without shift = 0.002

    16 18 20 22 24 26 28

    LSLLSL USLUSL66 66

    Q

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    KAI ENCONSULTANTS

    Q

    Sigma processes at a glanceSigma processes at a glance

    16 18 20 22 24 26 28

    LSLLSL USLUSL

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    Q

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    KAI ENCONSULTANTS

    Q

    Defects per Million Opportunities - BestDefects per Million Opportunities - Best

    Sigma levelSigma level DPMODPMOOneOne 3,17,3103,17,310

    TwoTwo 45,50045,500

    ThreeThree 2,7002,700

    FourFour 6363

    FiveFive 0.520.52

    SixSix 0.0020.002

    Q

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    KAI ENCONSULTANTS

    Q

    A practical situationA practical situation

    Keeping a process at the target,Keeping a process at the target,all the time, isall the time, is impossible.impossible.

    A process shift of 1.5A process shift of 1.5was observed atwas observed atMotorola.Motorola.

    Now widely agreeable.Now widely agreeable.

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    Q Defects per million opportunitiesDefects per million opportunities

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    KAI ENCONSULTANTS

    Q Defects per million opportunitiesDefects per million opportunitieswith shiftwith shift

    Sigma level DPMO (with shift)DPMO (with shift)

    1 697700697700

    2 308700308700

    3 6681066810

    4 62106210

    5 233233

    6 3.43.4

    Q

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    KAI ENCONSULTANTS

    Q

    Comparison best VS worst possibleComparison best VS worst possible

    Sigma level DPMO(without shift)

    DPMO(with shift)

    1 3,17,310 6,97,700

    2 45,500 3,08,7003 2,700 66,810

    4 63 6,210

    5 0.52 2336 0.002 3.4

    QS S ?

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    KAI ENCONSULTANTS

    Q

    What is Six Sigma?What is Six Sigma?

    Six Sigma refers itself to a statisticallySix Sigma refers itself to a statisticallyderived performance target of operatingderived performance target of operating

    with onlywith only 33.4 defects for every million.4 defects for everymillion

    activities or opportunities.activities or opportunities.

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    Q

    Si Si f l iSi Si f l i

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    Q

    Six Sigma a formal expressionSix Sigma a formal expression

    Six Sigma provides companies with aSix Sigma provides companies with a

    series of probesseries of probes andand statistical toolsstatistical tools thatthat

    can lead tocan lead to breakthrough profitability andbreakthrough profitability and

    quantum gains in quality.quantum gains in quality.

    Q

    Oth i f Si SiOth i f Si Si

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    KAI ENCONSULTANTS

    Q

    Other expression of Six SigmaOther expression of Six Sigma

    The Six Sigma strategy involves the use ofThe Six Sigma strategy involves the use of

    statistical toolsstatistical tools within structured methodologywithin structured methodology

    for gaining knowledge tofor gaining knowledge to achieve better, fasterachieve better, faster

    and lower cost products and servicesand lower cost products and services

    Q

    Wh t i Si Si ?Wh t i Si Si ?

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    KAI ENCONSULTANTS What is Six Sigma?What is Six Sigma?

    Six Sigma is a sweepingSix Sigma is a sweeping cultural changecultural change

    effortseffortsto position a company forto position a company forgreatergreater

    customer satisfaction, profitability andcustomer satisfaction, profitability and

    competitiveness.competitiveness.

    Q

    D i i f b hi d Si SiD i i f b hi d Si Si

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    KAI ENCONSULTANTS Driving force behind Six SigmaDriving force behind Six Sigma

    Six Sigma is driven by close understandingSix Sigma is driven by close understanding

    of theof the needs of customerneeds of customer,, disciplined use ofdisciplined use of

    factual data and statistical analysis,factual data and statistical analysis, whilewhilepaying diligent attention to manage,paying diligent attention to manage,

    improve and reinvent the business process.improve and reinvent the business process.

    Q

    Wh t Si Si d ?Wh t Si Si d ?

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    KAI ENCONSULTANTS What Six Sigma does?What Six Sigma does?

    Forces organisations to:Forces organisations to: Re-examine how the work gets doneRe-examine how the work gets done

    Simplifying the system and processSimplifying the system and process

    Improve capability of the processImprove capability of the process

    Find ways to control system andFind ways to control system and

    process permanently.process permanently.

    Q

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    KAI ENCONSULTANTS

    Q

    C t th tiCost mathematics

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    KAI ENCONSULTANTS Cost mathematicsCost mathematics

    Selling Price = Cost price + Profit

    Profit = Selling price - Cost price

    Q

    Val e added & non al e added acti itValue added & non value added activity

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    KAI ENCONSULTANTS Value added & non value added activityValue added & non value added activity

    CostPrice

    Cost ofnon value added

    activity

    Cost ofvalue added

    activity= +

    20 % 80 %

    50 %50 % 50 %50 %

    Q

    Non value added activitiesNon value added activities

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    KAI ENCONSULTANTS Non value added activitiesNon value added activities

    Over productionOver production

    WaitingWaiting

    TransportationTransportation

    InventoriesInventoriesNon conforming product leading to costNon conforming product leading to cost

    of poor qualityof poor quality

    Non involvement of the peopleNon involvement of the people

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    Q

    A ProcessA Process

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    KAI ENCONSULTANTS A ProcessA Process

    Key Process Output Variable, Y = f(X)Key Process Output Variable, Y = f(X)

    X1X1

    InputInput

    X2X2 X3X3

    X4X4 X5X5

    X6X6

    Value additionValue addition

    YY

    OutputOutput

    Q

    Process control & improvement modelProcess control & improvement model

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    KAI ENCONSULTANTS Process control & improvement modelProcess control & improvement model

    ManMan

    MachineMachine

    MaterialMaterial

    MethodsMethods

    MeasurementMeasurement

    MilieuMilieuInputInput

    CustomerCustomer

    OutputOutput

    DataData

    ProductProduct

    ServiceService

    ProcessProcess

    ProcessProcess

    SPCSPC

    Voice ofVoice of

    processprocess

    ChangingChanging

    needsneedsVoice of customerVoice of customer

    Q

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    KAI ENCONSULTANTS

    Q

    SIPOC ModelSIPOC Model

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    KAI ENCONSULTANTS SIPOC ModelSIPOC Model

    SupplierSupplier InputInput ProcessProcess OutputOutput CustomerCustomer

    CriticalCritical

    customercustomerrequirementsrequirements

    Q

    Effect of variationEffect of variation

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    KAI ENCONSULTANTS Effect of variationEffect of variation

    SupplierSupplier InputInput ProcessProcess OutputOutput CustomerCustomer

    Variation inVariation in

    inputinput

    Variation inVariation in

    processprocess

    Variation inVariation in

    outputoutput

    DefectsDefects

    A CO S A S

    Q

    Nature of customer requirementsNature of customer requirements

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    KAI ENCONSULTANTS Nature of customer requirementsNature of customer requirements

    Requirements of customer areRequirements of customer are

    dynamic in naturedynamic in nature and change withand change with

    the needs of customer.the needs of customer.

    KAI EN CONSULTANTS

    Q

    Current service requirementsCurrent service requirements

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    KAI ENCONSULTANTS

    0 5 10 15

    Current service requirementsCurrent service requirements

    Processing time in days

    Existingprocess

    KAI EN CONSULTANTS

    Q

    What Six Sigma organisation do?What Six Sigma organisation do?

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    KAI ENCONSULTANTS

    0 5 10 15

    What Six Sigma organisation do?What Six Sigma organisation do?

    Quality characteristics

    Existingprocess

    Improved

    processafter Six

    Sigmaproject

    Seeks to change location

    Reduce variation

    KAI EN CONSULTANTS

    Q New critical to customer requirementsNew critical to customer requirements

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    KAI ENCONSULTANTS 7 days7 days

    0 5 10 15

    NewrequirementImprovedprocess

    Number of days

    Oldrequirement

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    KAI EN CONSULTANTS

    Q

    Level of competitionLevel of competition

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    KAI ENCONSULTANTS Level of competitionLevel of competition

    Sigma DPMO

    Cost of poor

    quality(% of sales)

    Competitive

    level

    66 33..44 4400

    NNoonn

    ccoommppeettiittiivvee

    KAI EN CONSULTANTS

    Q

    Level of competitionLevel of competition

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    KAI ENCONSULTANTS Level of competitionLevel of competition

    1

    100

    10000

    1000000

    1 2 3 4 5 6

    Sigma Level

    P

    PM

    Noncompetitive

    Industryaverage

    Worldclass

    KAI EN CONSULTANTS

    Q

    Times improvement (Exponential)Times improvement (Exponential)

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    KAI ENCONSULTANTS Times improvement (Exponential)Times improvement (Exponential)

    Fromsigmalevel

    To sigma level3 4 5 6

    2 5 55 1485 1,02,465

    3 11 297 20,493

    4 27 1863

    5 69

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    KAI EN CONSULTANTS

    Q

    33 VS 6VS 6 supplier performance gapsupplier performance gap

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    KAI ENCONSULTANTS

    Event 3-Sigma 6-SigmaWrong drugprescription

    54,000/year 1 in 25 years

    Unsafe drinkingwater 2 hours/month

    1 sec in 25years

    Incorrect surgicaloperation

    1,350 / week 1 in 20 years

    Lost article in post 54,000 perhour

    35 in a year

    33 VS 6VS 6 supplier performance gapsupplier performance gap

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    KAI EN CONSULTANTS

    QBenefits of Six Sigma - #1Benefits of Six Sigma - #1

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    KAI ENCONSULTANTS Benefits of Six Sigma #1g

    Generates sustained success.Generates sustained success.

    - generally business life of a product- generally business life of a productis 3 years.is 3 years.

    - To survive we must have double- To survive we must have double

    digit growth.digit growth.- constantly innovates and- constantly innovates and

    restructures the organisation.restructures the organisation.

    KAI EN CONSULTANTS

    QBenefits of Six Sigma - #2Benefits of Six Sigma - #2

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    KAI ENCONSULTANTS e e s o S S g a #g

    Sets performance goals forSets performance goals for

    every oneevery one uses common business frameuses common business frame

    workwork

    ensures consistency for meetingensures consistency for meeting

    customer requirements.customer requirements.

    KAI EN CONSULTANTS

    QBenefits of Six Sigma #3aBenefits of Six Sigma #3a

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    KAI ENCONSULTANTS gg

    Enhances value to customer

    We want to make our quality soWe want to make our quality so

    special, so valuable to customer,special, so valuable to customer,

    so important to their success thatso important to their success thatour productsour products become their onlybecome their only

    real choice.real choice.

    Jack WelchJack Welch

    KAI EN CONSULTANTS

    QBenefits of Six Sigma #3bBenefits of Six Sigma #3b

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    KAI ENCONSULTANTS gg

    Good and defect free productGood and defect free product

    does not guarantee success.does not guarantee success.

    The focus on customers in SixThe focus on customers in Six

    Sigma meansSigma means whatwhatvalue meansvalue meansto customer and planningto customer and planning howhowtoto

    deliver them profitably.deliver them profitably.

    KAI EN CONSULTANTS

    QBenefits of Six Sigma - #4Benefits of Six Sigma - #4

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    KAI ENCONSULTANTS gg

    Accelerates the rate of improvementAccelerates the rate of improvement

    100 times improvement in four years100 times improvement in four years

    at Motorola.at Motorola.

    it helps companies not only toit helps companies not only toimprove performance, butimprove performance, but

    improve the improvementimprove the improvement

    KAI EN CONSULTANTS

    QBenefits of Six Sigma - #5Benefits of Six Sigma - #5

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    KAI ENCONSULTANTS gg

    Promotes Learning and Cross PollinationPromotes Learning and Cross Pollination

    Accelerates development and sharing of newAccelerates development and sharing of new

    ideas throughout the organisationideas throughout the organisation..

    Six Sigma is data based and therefore applicableSix Sigma is data based and therefore applicable

    to any functional areato any functional area..

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    KAI ENCONSULTANTS

    QProven benefits of Six SigmaProven benefits of Six Sigma

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    gg

    Cost reductionCost reduction

    Productivity improvementProductivity improvement

    Market-share growthMarket-share growth

    Customer retentionCustomer retention

    Cycle reduction timeCycle reduction time

    Defect reductionDefect reduction Cultural changeCultural change

    Product / service changeProduct / service change

    KAI ENCONSULTANTS

    Q

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    KAI ENCONSULTANTS

    QSix Sigma at MotorolaSix Sigma at Motorola

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    Todays existence due to Six SigmaTodays existence due to Six SigmaInvented for survivalInvented for survival

    Method for tracking companys performanceMethod for tracking companys performancevis a vis customer requirementvis a vis customer requirement

    Improvement 10X in two years orImprovement 10X in two years or100X in100X in

    four yearsfour years

    KAI ENCONSULTANTS

    QResults of Six Sigma at MotorolaResults of Six Sigma at Motorola

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    Five fold growth in salesFive fold growth in sales

    Annual increase of profit 20%Annual increase of profit 20%

    Cumulative saving $14 BillionCumulative saving $14 Billion Annual stock price gain 21.3 %Annual stock price gain 21.3 %

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    KAI ENCONSULTANTS

    QBottom line improvement at GEBottom line improvement at GE

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    Launched Six Sigma in 1995Launched Six Sigma in 1995

    Profit by 1998Profit by 1998 $750 Million$750 Million

    Profit by 1999Profit by 1999 $ 1.5 Billion$ 1.5 Billion

    Cutting invoice defect by 98%Cutting invoice defect by 98%

    Streamlining of contract review - $1 Million/yearStreamlining of contract review - $1 Million/year

    GE Medical body scan time 3 minute to .5 minuteGE Medical body scan time 3 minute to .5 minute GE Mortgage Call reaching person 76% to 99%GE Mortgage Call reaching person 76% to 99%

    KAI ENCONSULTANTS

    QJack Welchs important discoveryJack Welchs important discovery

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    One thing we discovered with certainty isOne thing we discovered with certainty is

    that anything we do that makes thethat anything we do that makes the

    customer more successfulcustomer more successfulinevitablyinevitablyresults inresults in financial returnfinancial return to us.to us.

    KAI ENCONSULTANTS

    QAs per GE, Most Important oneAs per GE, Most Important one

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    KAI ENCONSULTANTS

    QExplanation of Jack WelchExplanation of Jack Welch

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    The best Six Sigma project begin notThe best Six Sigma project begin notinside the business but outside it.inside the business but outside it.

    Focused on answering the question howFocused on answering the question how

    can we make customer competitive.can we make customer competitive.

    Knowing what is critical to customer andKnowing what is critical to customer and

    providing it.providing it.

    KAI ENCONSULTANTS

    Q

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    KAI ENCONSULTANTS

    QResults at Allied SignalsResults at Allied Signals

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    Savings of $600 million per year Reduction in time from drawing to

    certification of aircraft engines from 42

    months to 33 months.

    Increase in productivity by 6 %

    Increase in market share 27% annually

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    KAI ENCONSULTANTS

    Q

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    We cannot go on with thisWe cannot go on with this

    KAI ENCONSULTANTS

    QNew Operating philosophyNew Operating philosophy

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    BulletBulletTrain PhilosophyTrain PhilosophyBulletBulletTrain PhilosophyTrain Philosophy

    KAI ENCONSULTANTS

    Q

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    KAI ENCONSULTANTS

    QKaizen in JapanKaizen in Japan

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    WorkerWorker

    SupervisorSupervisorMiddleMiddle

    TopTop

    Percentage of time

    JapanJapan

    Improvem

    ent

    Maint

    enance

    KAI ENCONSULTANTS

    QKaizen in USA/EuropeKaizen in USA/Europe

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    100% maintain100% maintain

    100% maintain100% maintain

    WorkerWorker

    SupervisorSupervisorMiddleMiddle

    TopTop

    Percentage of time

    USA/EuropeUSA/Europe

    KAI ENCONSULTANTS

    QCulture at worst companiesCulture at worst companies

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    100% maintain100% maintain

    100% maintain100% maintain

    100% maintain100% maintain

    100% maintain100% maintain

    WorkerWorker

    SupervisorSupervisorMiddleMiddle

    TopTop

    Percentage of time

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    KAI ENCONSULTANTS

    QChanging criteriaChanging criteria

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    A B C X

    P-Criteria R-CriteriaR-Criteria

    Effort to Improve

    Support & Stimulate PerformancePerformance

    Control withControl with

    Carrot & StickCarrot & Stick

    KAI ENCONSULTANTS

    QBasic philosophy of qualityBasic philosophy of quality

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    Whatever measured must beWhatever measured must be recordedrecorded

    Records must beRecords must be analyzedanalyzedusingusing

    statistical techniques.statistical techniques.

    Information obtained must beInformation obtained must be actedacted

    uponupon..

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    KAI ENCONSULTANTS

    QOld waysOld ways

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    KAI ENCONSULTANTS

    QGoal Post StrategyGoal Post Strategy

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    Sudden

    Loss

    Sudden

    Loss

    LSL USL

    TargetTarget

    Good product Bad product

    KAI ENCONSULTANTS

    QInterpretation of DataInterpretation of Data

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    Sudden

    Loss

    Sudden

    Loss

    LSL USL

    Target

    ABC

    KAI ENCONSULTANTS

    QTaguchis loss functionTaguchis loss function

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    USLLSL

    Best

    Good Good

    Fair Fair

    Poor Poor

    Custom

    er

    Dissatisfa

    ction

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    KAI ENCONSULTANTS

    Q Implementing Six sigmaImplementing Six sigma

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    1.1. Emphasizing sigma level as aEmphasizing sigma level as a

    standard metric that can be appliedstandard metric that can be applied

    to all parts of organisationto all parts of organisation

    ManufacturingManufacturing

    EngineeringEngineering

    AdministrativeAdministrative SoftwareSoftware

    KAI ENCONSULTANTS

    Q Implementing Six sigmaImplementing Six sigma

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    2.2. Providing extensive trainingProviding extensive training

    followed by deployment of team onfollowed by deployment of team onproject for:project for:

    Improving profitabilityImproving profitability

    Reduce non value added activitiesReduce non value added activities

    Reduction in cycle timeReduction in cycle time

    Simplifying the proceduresSimplifying the procedures

    KAI ENCONSULTANTS

    Q Implementing Six sigmaImplementing Six sigma

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    3.3. Focusing on corporate sponsors for:Focusing on corporate sponsors for:

    Supporting team activities.

    Helping to overcome resistance to

    change.

    Obtain resources

    KAI ENCONSULTANTS

    Q Implementing Six sigmaImplementing Six sigma

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    4. Creating highly qualified process

    improvement experts: Green belt

    Black belt

    Master black belt

    Who can apply improvement toolsWho can apply improvement tools

    KAI ENCONSULTANTS

    Q Implementing Six sigmaImplementing Six sigma

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    5.5. Early identification of appropriateEarly identification of appropriate

    metric that focuses on businessmetric that focuses on business

    results.results.

    6.6. Setting stretch objectives forSetting stretch objectives for

    improvement.improvement.

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    KAI ENCONSULTANTS

    Q Key principles for effectiveKey principles for effectiveimplementation of Six Sigmaimplementation of Six Sigma

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    Involved leadershipInvolved leadership

    Leading with aggressive goalsLeading with aggressive goals

    Spending time in Six Sigma training waveSpending time in Six Sigma training wave

    Dropping in Six Sigma reviewsDropping in Six Sigma reviews

    Gathering first hand informationGathering first hand information

    Monitoring Six Sigma progressMonitoring Six Sigma progress

    KAI ENCONSULTANTS

    Q Key principles for effectiveKey principles for effectiveimplementation of Six Sigmaimplementation of Six Sigma

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    Process thinkingProcess thinking

    Mapping of all business processes and keyMapping of all business processes and key

    activities.activities.

    Disciplined customer and marketDisciplined customer and market

    intelligence gatheringintelligence gathering

    Knowledge of customers need is vitalKnowledge of customers need is vital

    Bottom line orientationBottom line orientation

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    KAI ENCONSULTANTS

    Q

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    KAI ENCONSULTANTS

    Q Process Map for Six Sigma ProjectsProcess Map for Six Sigma Projects

    kD t i k

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    Determine keyDetermine key

    customer orcustomer or

    business needbusiness need

    Apply QFD toApply QFD to

    determinedetermine

    projectproject

    opportunitiesopportunities

    ViableViable

    projectproject

    DetermineDetermine

    baseline andbaseline and

    bottom linebottom line

    benefitsbenefitsProject charterProject charter

    and overall planand overall plan

    Stored ideas forStored ideas for

    future projectsfuture projects

    No

    Requiresteam &

    analysis

    Yes

    Motivate

    d team?No

    Scope ofScope of

    projectproject

    Yes Lowhangingfruits

    NoDetermineDetermine

    metrics andmetrics and

    goalsgoals

    YesBig

    hitter?

    No

    Project executionProject execution

    PresentationPresentation

    Yes

    KAI ENCONSULTANTS

    Q Breakthrough StrategyBreakthrough Strategy

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    Define opportunities What is important?Define opportunities What is important?

    Measure performance how are we doing?Measure performance how are we doing?

    Analyse opportunities what is wrong?Analyse opportunities what is wrong?

    Improve performance what needs to be done?Improve performance what needs to be done?

    Control performance how do we generate & sustainControl performance how do we generate & sustain

    performance?performance?

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    KAI ENCONSULTANTS

    Q

    66 is extensively data drivenis extensively data driven

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    yy

    We need smart Statistical analysis toolsWe need smart Statistical analysis tools

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    KAI ENCONSULTANTS

    Q CE-Diagram for defective ItemsCE-Diagram for defective Items

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    DefectiveItems

    Materials Method

    Machine Man

    SourceProcedure

    Layout

    Mood

    AttitudeTraining

    Shape

    Wobble

    AccuracyMake

    KAI ENCONSULTANTSQ Pareto Analysis For PrioritizationPareto Analysis For Prioritization

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    0

    50

    100

    150

    200

    A B C D E F G H

    Events

    Frequency

    KAI ENCONSULTANTSQ HistogramHistogram

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    0

    2

    4

    68

    1 0

    1 2

    1 4

    1 6

    4 0 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 5 0 5 1

    KAI ENCONSULTANTSQ Normal probability plotNormal probability plot

    13

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    5

    7

    9

    11

    13

    -3 -2 -1 0 1 2 3

    Z

    X

    Used for assessing -Used for assessing - Normality of distributionNormality of distribution

    KAI ENCONSULTANTSQ Typical control chartTypical control chart

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    48.0

    48.5

    49.0

    49.5

    50.0

    50.5

    51.0

    51.552.0

    0 5 10 15 20 25

    Sample No.

    Samp

    leMean

    UCL

    CL

    LCL

    KAI ENCONSULTANTSQ Gauge repeatability & reproducibilityGauge repeatability & reproducibility

    studiesstudies

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    Reproducibility

    RepeatabilityRepeatability

    Inspector

    A

    RepeatabilityRepeatability

    InspectorB

    Variable Scale

    KAI ENCONSULTANTSQ Scatter DiagramScatter Diagram

    100

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    40

    50

    60

    7080

    90

    100

    40 50 60 70 80 90 100Quiz Average

    FinalAverage

    KAI ENCONSULTANTSQ Realistic tolerance and realisticRealistic tolerance and realistic

    specificationspecification

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    50.0

    55.0

    60.0

    65.0

    70.0

    100 105 110 115 120 125 130

    Air Pressure

    WallThickness

    Realistic Tolerance

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    KAI ENCONSULTANTSQ Analysis of VarianceAnalysis of Variance

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    Identifying which of the factors are

    responsible for variation in out quality

    characteristics.

    One way ANOVA

    Two way ANOVA

    GRRS, DOE, Process Capability,Relationship

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    KAI ENCONSULTANTSQ Correlation & Regression AnalysisCorrelation & Regression Analysis

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    X2X2

    X4X4

    YYX3X3X1X1

    Y = f(XY = f(X11, X, X22, X, X33,),)

    KAI ENCONSULTANTSQ

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    KAI ENCONSULTANTSQ

    ResponseResponse

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    ResponseResponse

    SurfaceSurfaceMethodologyMethodology

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    KAI ENCONSULTANTSQ Cumulative sum graphCumulative sum graph

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    0

    5

    10

    15

    20

    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

    Sample No.

    CUSUM

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    KAI ENCONSULTANTSQ

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    KAI ENCONSULTANTSQ

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    ThanksThanks