【正文】 a r g e tU S L0 . 0 00 . 0 00 . 0 00 . 0 00 . 0 00 . 0 00 . 0 00 . 0 00 . 0 01 . 9 91 . 9 91 . 9 91 . 9 91 . 9 91 . 9 61 . 9 61 . 9 61 . 9 65 . 0 2 4 9 25 . 1 0 7 4 65 0 0 7 0 . 0 2 8 4 0 . 0 0 0 7 0 . 0 0 01 0 0 . 0 0 0E x p e c t e d L T P e r f o r m a n c eE x p e c t e d S T P e r f o r m a n c eO b s e r v e d P e r f o r m a n c eO v e r a l l ( L T ) C a p a b i l i t yP o t e n t i a l ( S T ) C a p a b i l i t yP r o c e s s D a t aS TL T1 0 09 08 07 06 05 04 0U S LL S L6 S i g m a P r o c e s s w i t h 1 . 5 S i g m a S h i f tP P M T o t a lP P M U S LP P M L S LP P M T o t a lP P M U S LP P M L S LP P M T o t a lP P M U S LP P M L S LP p kP P LP P UP pC p mC p kC P LC P UC pS t D e v ( L T )S t D e v ( S T )S a m p l e NM e a nL S LT a r g e tU S L1 . 9 31 . 9 30 . 0 02 . 5 82 . 5 80 . 0 00 . 0 00 . 0 00 . 0 01 . 5 42 . 5 81 . 5 42 . 0 61 . 1 11 . 5 22 . 5 41 . 5 22 . 0 34 . 8 6 0 0 34 . 9 2 4 8 05 0 0 7 7 . 5 5 2 4 0 . 0 0 0 7 0 . 0 0 01 0 0 . 0 0 0E x p e c t e d L T P e r f o r m a n c eE x p e c t e d S T P e r f o r m a n c eO b s e r v e d P e r f o r m a n c eO v e r a l l ( L T ) C a p a b i l i t yP o t e n t i a l ( S T ) C a p a b i l i t yP r o c e s s D a t aS TL T14 Six Sigma Champion Training USL T m LSL 2 308,537 3 66,807 4 6,210 5 233 6 ? ? PPM PPM 20230 40000 60000 80000 100000 120230 140000 160000 0 20230 40000 60000 80000 100000 120230 140000 160000 3 4 5 6, 0 2 1 Sigma Shift PPM Sigma Shift Deeper Insight Into Shifts and Drifts 15 Six Sigma Champion Training 13 Short Term ? Long Term Short Term ? No Action No Action TO FROM + Long Term Six Sigma Conversion Table 16 Six Sigma Champion Training 3 4 5 6 7 1,000,000 100,000 10,000 1,000 100 10 1 2 Sigma PPM Domestic Airline Flight Fatality Rate PPM Restaurant Bills Doctor Prescription Writing Payroll Processing Order Taking Wire Transfers Airline Baggage Handling Purchased Material Reject Rate Average Company WorldClass Benchmarking Chart 17 Six Sigma Champion Training 3 Sigma 4 Sigma 5 Sigma 6 Sigma B A R R I E R ? Past success has bred arrogance ? Dependence on inspection and rework ? Reliance on trial and error ? Reward fire fighting behavior ? Little focus on quality measurements ? Functional departments inhibit cooperation Most Companies Why most Companies are 34 Sigma 18 Six Sigma Champion Training 3 Sigma 4 Sigma 5 Sigma 6 Sigma B A R R I E R ? Confidence in the opportunity ? Belief in the 6 Sigma methodology ? Ability to challenge the `Status Quo` ? Use of new skills, tools and information ? Use of new management behaviors Most Companies What is needed to reach 6 Sigma 19 Six Sigma Champion Training 3 Sigma 4 Sigma 5 Sigma 6 Sigma B A S I C T O O L S W A L L D E S I G N W A L L Seven Basic Quality Tools Green Belts Statistical Tools to Improve Processes Operational Black Belts Design for Six Sigma Engineering Black Belts Overing the Barriers 20 Six Sigma Champion Training Higher Quality, On Time Delivery Lower Cost Increases Customer Satisfaction ? Reduce the Cycle Time per unit ? Reduce WIP inventory carrying costs ? Reduce Delivered Defects ? Reduce early Failure Rates ? Reduce Repair Cost per unit We need a Focus on Total Defects Per Unit 21 Six Sigma Champion Training USFTY ?FTY= Final Test Yield S = Number of units that pass U =Number of units tested 2 01 91 81 71 61 51 41 31 21 11 09876543211 0 0 . 09 9 . 59 9 . 09 8 . 59 8 . 09 7 . 59 7 . 09 6 . 59 6 . 09 5 . 59 5 . 0R e p o r t i n g P e r i o dFinal Yield %Is Final Yield Correlated to Profit Margin? The Classical Perspective of Yield 22 Six Sigma Champion Training Is the Final Test Failure Rate Correlated to Profit Margin? 2 72 42 11 81 51 296302 72 42 11 81 51 29630F i n a l T e s t F a i l u r e R a t e %Profit Margin %Questioning the Basic Belief 23 Six Sigma Champion Training Is the Final Test Failure Rate Correlated to Scrap Rate? 2 72 42 11 81 51 296309876543210F i n a l T e s t F a i l u r e R a t e %Scrap Rate %Questioning the Basic Belief 24 Six Sigma Champion Training 4 . 44 . 24 . 03 . 83 . 63 . 43 . 23 . 02 . 82 . 62 . 41 0 09 89 69 49 29 08 88 68 48 28 0P r o c e s s C a p a b i l i t y ( S i g m a )Final Test YieldWhat Does this Imply? Final Test Yield is Correlated to Process Capability 25 Six Sigma Champion Training Verify 90 Units Passed Final Test YFT = 90% Operation Not OK Rework Scrap DPU = 100 Units Start 37 Units d = 0 63 Units d 1 10 Units Scraped 53 Units Repaired ?Defect Type Count A 25 B 15 C 5 D 20 E 35 Total 100 YTP = 37% Throughput Yield Units with Zero Defects Process Capability = 37% not 90% Unlocking the Hidden Factory 26 Six Sigma Champion Training The Idea of Rolled Throughput Yield RTY or YRT Input Step 1 YTP1 Step 2 YTP2 Step 3 YTP3 … Step K YTPK Output YRT = e TDPU YRT = P Y TPJ K J=1 YRT = Probability of a Unit going through all Process Steps with zero defects YRT = YTP1 x YTP2 x YTP3 x …. Y TPK If TDPU = .25, then YRT = = % 27 Six