【正文】 trative Areas6? Customers or Suppliers: One opportunity per product delivered or per ponent purchased. Manufacturing process: ? ?Opportunities at each process step) Administrative areas: Number of opportunities for error for each activity performed The Opportunities... 14 6Sigma Training Some Examples of Opportunity Customer Perspective: 1 opportunity per product delivered ex. 1 regulator = 1 opportunity 1 controller = 1 opportunity Production lines: Regulator = 160 opportunities Controller = 1200 opportunities Form( Payment, Purchase Order, .. ): Number of fields Expedite / Delivery: 1 opportunity / packaging unit 15 6Sigma Training A quality level of 6? corresponds to less than defects per million Opportunities ( ., correct % of the time ) Sigma and Opportunities 16 6Sigma Training A Universal Measurement Scale ... 3 4 5 6 7 66810 6210 233 ? Sigma DPMOp On one condition : Calculate the defects and estimate the opportunities in the same way... 17 6Sigma Training Measurement With SIGMA Is Simple !!! Estimate the Opportunities Count the Defects Follow the Indicator : Defects per million Opportunities Conversion into Sigma can be acplished with the help of a statistical table . 6? = dpmo 18 6Sigma Training Converting Defect Levels to..... Sigma ! 175 defects are identified while producing 5000 controllers The manufacture of one controller allows for 1367 defect opportunities. = / 1367 = An Example : = 175 / 5000 = = Sigma level : 19 6Sigma Training Six Sigma: An Ambitious Objective? ? Accurate to % ( less than defects for each million opportunities ) could appear excessive....! % is already VERY GOOD ! But what could happen at a quality level of % (., 1000 ppm), in our everyday lives (about ?)? ? 4000 wrong medical prescriptions 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 identificati