【正文】 each year ? More than 3000 newborns accidentally falling from the hands of nurses or doctors each year ? Two long or short landings at American airports each day ? 400 letters per hour which never arrive at their destination 20 6Sigma Training The Impact of Quality: “6 Sigma Suppliers” ? 13 wrong drug prescriptions per year ? 10 newborn babies dropped by doctors/nurses per year ? Two short or long landings per year in all the airports in the . ? One lost article of mail per hour 21 6Sigma Training Defect Reduction: “Peeling the Onion” ? Action Name Date ACTION PLAN PROCEDURE CONTINUOUS IMPROVEMENT MODEL TREND CHART GOAL T I M E 100% BRAINSTORMING/ PARETO ANALYSIS/ ROOT CAUSE IDENTIFICATION RESULTS AND INSTITUTIONALIZE MEASURE ANALYZE PROBLEM SOLVE Process step 1 Process step 3 Process step 2 ? ? ? ? SUPPLIER CUSTOMER RECORD DEFECTS RECORD DEFECTS RECORD DEFECTS RECORD DEFECTS RECORD DEFECTS 22 6Sigma Training Measurement Systems Capability The capability of the measurement system must be ensured before the system is used for process control or for measurements used in capability studies. Gage Repeatability Reproducibility (RR) : ? is a statistical study to investigate the gage’s ability to repeat a measurement on the same part (repeatability) an dthe ability to give the same reading on the same part when used by different people (reproducibility). ? Under 10% acceptable ? 10% 30% May be acceptable depending on application. Effort should be made to improve the gaga capability. ? Over 30% Not suitable to use. 23 6Sigma Training Gage R R 24 6Sigma Training Process Performance Capability To measure the ability of a machine or process to produce a product within specification. Potential Process Capability Index (Cp) : Ratio of specification width over the process spread Spec Width Cp = Process Spread USL LSL = 6 Sigma 25 6Sigma Training Process Performance Capability Process Capability Index (CpK) : an offtarget process should be “penalized” for shifting from where it should be. CpK is the index to measure this real capability when the offtarget penalty is taken into consideration. Target Process Mean Penalty/Correction factor, k = 1/2 Specification Width Mean Closer spec limit Cpk = Cp (1 k) = 3 sigma 26 6Sigma Training Process Performance Capability 27 6Sigma Training Process Performance Capability * Maximum customer satisfaction is achieved only when the product is right on target. 28 6Sigma Training Process Performance Capability 29 6Sigma Training Total Process Control System 1. Process / Product Failure Mode and Effects Analysis (FMEA) ? An analytical technique aimed at problem prevention through identification of potential problems. For each failure mode, the effect on the total system is studied and actions to minimize the probability of failures are planned. ? FMEA will serve : a) Identifies known or potential process failure modes b) Assesses the potential risk effects of the failures to the customer c) Identifies the potential product or manufacturing process causes and control actions d) Identifies significant process variables to focus controls for detecting and reducing similar failures 30 6Sigma Training FMEA 31 6Sigma Training Total Process Control System 2. Process Control Plan ? A summary description of the procedures for controlling all significant characteristics of the processes used to manufacture a family of similar products. It identifies the important processes used to produce a product, the significant characteristics associated with each process and how to control each of those significant characteristics. ? Control Plan consists : a) Process b) Equipment c) Significant characteristics d) Measurement method e) Minimum sample size and frequency f) Analysis method g) Out of control action 32 6Sigma Training Control Plan P r e p a r a t i o n I ns p e c t i o n P r o c e s sS a m p l e F r e q ue nc y 1 w a f e r 1 w a f e r / l o tI d i e I d i e / w a f e r / l o tc r o s s l i n e 5 w f r s / l o tt h r u c e n t e r A f t e r s p u t t e r i n g q u a l i t y5 d i e / w f r1 W a f e r / 5 W a f e r1 W a f e r / 5 W a f e r5 d i e / w f r1 W a f e r / 5 W a f e r1 W a f e r / 5 W a f e r5 d i e / w f r 1 W a f e r / 1 W a f e rT i m e r a l a r m t i t r a t i o nc r o s s l i n et h r u c e n t e r5 d i e / w f rc r o s s l i n e 1 W a f e r / 1 W a f e rR u n c a r d 6 d ( 1 )R u n c a r d 6 h ( 1 )R u n c a r d 6 I ( 1 )R u n c a r d ( s p u t t e r P Q C P r o c e s s )M e t ho d1 W a f e r / 1 W a f e rR u n c a r d 5 e ( 1 )R u n c a r d 5 d ( 2 )R u n c a r d 3 e ( 2 )R u n c a r d 3 e ( 3 )R e c o r dB a r e e y e m i c r o s c o p e