【正文】 s, automotive applications driven by liability costs ◆ Later the automotive industry saw the advantages of using this tool to reduce risks related to poor quality. ◆ Early 80’s: Micro Electronic Industry started to apply FMEA to assist in improving the ―yield of memory devices‖. ? Mid 80’s: Automotive industries started to apply FMEA to the manufacturing processes. ? 90’s: TQS 9000 remended adoption of FMEA. Six 6s Sigma Where do Risk Come From Cumulative Risk : ① Raw Material Variation ② Poorly developed Specification Limits ③ Measurement Variation ( Online and QC ) ④ Machine Reliability ⑤ Vague Workmanship Standards ⑥ Unclear customer Expectations ⑦ Potential Safety Hazards ⑧ Poor control plans SOP’ s ⑨ Poor Process capability Failure Mode and Effects Analysis Six 6s Sigma Type of FMIEA39。sinput type Major Step Subprocess outputKPIV39。Six 6s Sigma Six 6s Sigma What is SixSigma Key Terms Six Sigma A term coined by Motorola to express process capability in parts per six sigma process generates a defect probability of parts per million (PPM) Champion An upper level business leader who facilitates the leadership,implementation,and deployment of six sigma philosophies. Black Belt A process improvement project team leader who is trained and certified in sixSigma methodology and tools and who is responsible for project execution. Mater Black Belt A person who is an “ expert ” on Six Sigma techniques and on project implementation,master Black Belt play a key role in training and coaching of Back and Green Belts. Green Belt Six Sigma role similar in function to Black Belt but length of training and project scope are reduced to two weeks of training. Six 6s Sigma Key Terms Yellow Belt Hourly personnel trained in the fundamentals of sixsigma who assist and support in project execution ,usual work with black and Green Belt. Process Map A stepbystep pictorial sequence of a process showing process inputs,process outputs,cycle time ,rework operations,and inspection points. Key process Inputs Variable (KPIV) The vital few input variables,call “ x” s Key process outputs Variable (KPOV) The output variables,call “ x” s DFMA Design for manufacture and assemble, A methodology to reduce product plexity and design around more capable ponents / processes Cost of poor quality Cost associated with Providing poor quality products or services. Can be divide into four cost categories :Appraisal ,Scrap, Rework,and field Complaint What is SixSigma Six 6s Sigma What is SixSigma ? Vision ? Philosophy ? Aggressive Goal ? Metric (Standard of measurement ) ? Benchmark ? Method ? Tools for : ? Customer focus ? Breakthrough Improvement ? Continues improvement ? People Involvement SixSigma is a problem solving process used to produce: Reduced variation in our processes / Products ? improved RTY , DPU, DPPM / Reduced cost of poor quality (COPQ) / improved capacity and productivity ? $$’ s What is SixSigma Six 6s Sigma SixSigma can be applied to every business function SixSigma DESIGN PURCH. MFG MAINT. QA ADMIN. SERVICE What is SixSigma Six 6s Sigma SixSigma Focus : ? Delighting the Customer Through Flawless Execution ? Rapid Breakthrough Improvement ? Advanced Breakthrough Tools that work ? Positive and Deep Culture Change ? Real Financial results : Passion +Execution = Fast and Lasting Results Who else in the has started Six Sigma ? Motorola ( 1987 ) ? Texas Instruments (1988 ) ? IBM (1990 ) ? ABB (1993 ) ? Alliedsignal / Koadk (1994 ) ? GE (1995 ) ? Whirlpool ,Bombardier, Polaroid , Siebe PACCAR ( 1996 / 98 ) What is SixSigma Six 6s Sigma ? Value Analysis ? Concept Engineering ? K J methodology QFD ? Process Map ? Cause and effect matrix ? Measurement system analysis ? capability analysis ? Descriptive statistics ? Graphical techniques Box Plots / Histograms / Scatter plots / Run charts Pareto charts / check sheets / Time series plots ? Statistical process control chart ? Correlation ? Simple multiple regression ? MultiVari studies Top Tools What is SixSigma Six 6s Sigma ? Inferential statistics Central limit theorem Confidence interval ? Failure mode and effect analysis Design Process ? Fraction factorial experiments ? Full factorial experiments ? Response surface methods ? Transformations ? Normal distribution ? Sample size determination ? Screening studies ? Statistical Tolerancing ? Design for manufacturability ? Design for quality ? Hypothesis testing ? Ftest ? Chisquare test ? Tests for normality ? Analysis of Variance Top Tools What is SixSigma Six 6s Sigma ISO Requires SixSigma Delivers Prevention of Defects all Stages from Design through servicing OK Identifying the need for statistical techniques require for establishing ,controlling and verifying process capability and product characterization . OK Investigation of the cause of defects relating to product , process and quality system . OK Continuous improvement of quality of products and services OK ISO and SixSigma What is SixSigma Six 6s Sigma Leading SixSigma In Operations ? Select the Right project : ? Clarify Big Picture using Strategic Plan ? Establish Plant / productivity baseline ? Prioritize projects base on value,resources req’ d timing ? Select key projects with leadership buyin ? Check accountability : business and personal ? Select and train the Right people ? Ensure the right leadershi