【正文】 e defects less than DPMO(PPM). LSL USL ? ？ ? Defect M 6? in RD 6? in MFG. Company Customer Customer CTQ VOC VOB 6? DPMO New Std. 3? 66800 DPMO Past Std. 27 ? How Do We Improve Process Capability? ? ? Increase the tolerance ? ? Decrease the spread or variation of the process ? ? Shift the average by: ? ? ? Centering the average if the spec. has two limits ? ? ? Decrease or increase the average for spec. with one limit 28 ? The Cost Opportunity ? 2? 3? 4? 5? 6? 0 5 10 15 20 25 30 About 15% of Sales, Cost Opportunity on 3? Company Cost of Failure (% of Sales) 29 ? The Cost of Poor Quality (COPQ) Long Cycle Times, More Setups, Expediting Costs, Lost Sales, Engineering Change order, Overtime, Late delivery, Lost Opportunity, Lost Customer Loyalty, Excess Inventory Rejects, Warranty, Inspection, Scrap, Rework 30 ? Who is Implementing 6 ? ? Motorola 1987 ? Texas Instrument 1988 ? ABB (Asea Brown Boveri) 1993 ? Allied Signal 1995 ? General Electric 1995 ? Kodak 1995 ? Siemens, Nokia, Sony 1997 31 ? 6 ? Benefits(Case 1) Motorola over 12 yrs ? Increase productivity an average of % per year ? Reduced the cost of poor quality by more than 84% ? Eliminated % of in process defects ? Save more than $11billion in manufacturing cost ? Realized an average annual pounded growth rate of 17% in earnings 32 ? 6 ? Benefits(Case 2) General Electric (Million Dollars) Cost Profit 1996 240, 200 1997 400, 700 1998 450, 1200 1999 520, 2520 2023 600, 3000 33 ? 6 ? Benefits( Case 3) Texas Instruments Before (1988) After (1993) COPQ 30% 7% DPMO 104000 9000 Scrap $3M $ Yield % % Cycle Time (Week) 11 4 Inventory Cost $ $ 34 ? The Focus of 6 ? If we are perfectly control X, should we constantly test and inspect Y? Y = f (X) Y X1 X2 X3 X4 X X …Xn ◎ Independent ◎ InputProcess ◎ Cause ◎ Problem ◎ Control Y ◎ Dependent ◎ Output ◎ Effect ◎ Symptom ◎ Monitor 35 ? 6 ? is Applying Overall Business System RD 6? Transaction Mfg Design SS Manufacturing SS Transactional SS 36 ? 6 ? Methodology Measure Analyze Design Verify Measure Analyze Improve Control Define Translate Y N New Process/ Product ? Achievable Goal ? N Y 37 ? What is different with 6 ? Traditional Quality 6? ◎ Central Organized ◎ Not Formal Structure for Tool Application ◎ Lack of Support in using Tools ◎ Lack of Structured Training ◎ Inspect Quality in (Focus on “ Y” ) ◎ Black Belt Report Directly Into Function ◎ Structured Use of Statistical Tools to Aid Problem Solving ◎ DataBased Decisions ◎ Structured Training in Applied Statistics ◎ Control Process Input (X’ s) 38 ? 6 ? Organization ? 6 ? Organization ◎ Executive Project Selection and Support ◎ 6?Technical Lead 6? Coach Project BB ◎ 6? Project Team Lead ◎ 6? Project Team Member ◎ All staffs (6? overview) Champion Master Black Belt (MBB) Black Belt (BB) Green Belt (GB) White Belt (WB) 39 ? 3. 6 ? Methodology ? 5 Stage of DMADV and New Tools Design For Six Sigma (DFSS) Black Belt ? 5 Stage of DMAIC methodology Green Belt 40 . DMAIC Methodology 5 Stages DMAIC Methodology and Statistical Tools ? Phase: Define ? Steps。 Work Breakdown Tool ? D1 Validate Business Opportunity。 ? 3C Analysis, Identify Customer, Cost/Effect Analysis ? D2 Define Customer Requirement。 ? VOC, VOB, QFD ? D3 Project Planning。 ? Project Team, Project Charter, COPQ 41 ? Define Steps (1) Vision Business Strategy Big Y (CTQ) Small y Project (Goal, Scope, Performance Index) 42 ? Define Steps (21) ? Vision:最具競爭力的企業(yè) (GE) ? StrategyThe Three Circle (GE) 核心事業(yè) ◎ 照明 ◎ 大型家電 ◎ 馬達 高科技事業(yè) ◎ 醫(yī)療系統(tǒng) ◎ 工業(yè)電子 ◎ 航太 服務事業(yè) ◎ 信用公司 ◎ 資訊服務 ◎ 核能服務 43 ? Define Steps (22) The Three Circle (GE) ? Jack Welch (GE’ S CEO)畫三個圓圈：核心、高科技與服務。 GE公司未來都要在其中一個圓圈內。公司任何人不再任一個圓圈內者，未來將會被解雇。圓圈外的的事業(yè)將被整頓、關閉或出售。三個圓圈的策略讓 GE公司找到焦點，不再是集團 (似乎什麼都做 )。 44 ? Define Steps (3) Select Target Product/Service Analysis Business Process Analysis Core Process Identify Customer Listen to VOC Specify Customer Requirement Select CTQ (Big Y) Specify CTQ (Small Y) Evaluate Potential Projects Select Project Build Effective Team 45 ? Define Steps (4) ? CTQ Critical to Quality ? 只要是顧客要求的 ， 就是關鍵品質(CTQ)。 亦稱為 『 重要成果 』 、 『 特殊限制 』 或流程的 『 Y變數(shù) 』 。 CTQ係任何會直接影響顧客對產(chǎn)品 /服務品質觀感之因素 。 顧客 『 在乎 』 的事 ， 就是企業(yè)或組織在乎的事 。 『 新點子 』 要採納『 外部觀點 』 (Outsidein Perspective)，即從顧客的眼光來看企業(yè)或組織的一切 。 46 . DMAIC Methodolo