Introduction to Lean Six Sigma
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Transcript of Introduction to Lean Six Sigma
Introduction to Lean Six Sigma
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Learning Outline
• What is Six Sigma • The Six Sigma Philosophy • Brief History of Six Sigma • DMAIC Methodology
– Define – Measure – Analyze – Improve – Control
• Why DMAIC is different from other Quality Models
• Six Sigma Certifications• Six Sigma Roles • Recap
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What is Six Sigma (6σ)
Six Sigma (6σ) represents the level of quality when the defects are
decreased to 3.4 in 1,000,000 million opportunities
Few Examples Out of 1,000,000 parcels a courier company delivers apprx. 999,996 parcels on time while approx only 4 are delayed !
Out of 1,000,000 service hours a telecom company’s service are up 999,996 hours while experiencing the down time of only 4
hours!
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What is Six Sigma (6σ)
1,000,000 Opportunities
• Have you noticed the large sample size – i.e. 1,000,000 ? • What if we don’t have 1,000,000 samples / opportunities
…… well lets run few quick tests
25,000 Opportunities 150 Opportunities
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Six Sigma Philosophy The quality of the product /service depends on the
process used to develop that product/service
Six Sigma : Improves the underlying business process Is Customer focused Uses statistical tools
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Brief History of Six Sigma
In 1818 Johann Carl Gaussian introduces concept of Normal Distribution – the basis of Six Sigma
Bill Cohen – an engineer in Motorola coined the term Six Sigma for the firs time
Bill Smith in 1986 standardized the Six Sigma i.e. 1 Mil Opportunities
Motorola , Citibank , general Electric and Allied Signals were the early adapter of Six Sigma
Motorola reported $ 16 Billion savings due to Six Sigma Adoption
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DMAIC Methodology DMAIC is abbreviation of the 5 key steps required to
run Six Sigma projects
DMAIC
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Define Phase – Steps & Tools Define
Develop Charter and Business Case
SIPOC
Map Existing Processes
Process Mapping
Value Stream Mapping
Spaghetti Chart
Collect Voice of Customer
VOC
Affinity Diagram
Specify CTQ Requirements
CTQ Tree
Step Tools
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Measure Phase – Steps & Tools Measure
Measure CTQs
CTQ Tree
Determine Process Stability
Statistical Process Control
Data & Data Collection
Data collection Check Sheet
Validate Measurement System
R& R gauge
Establish Process Capability
Calculating Cp & Cpk
Histogram
Step Tools
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Analyze Phase – Steps & Tools Analyze
Identify Root Causes
5-Whys
Fishbone Diagram
Quantify Root Causes
FMEA Tools
Verify Root Causes
Scatter Plot
Correlation and Regressions Analysis
Step Tools
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Improve Phase – Steps & Tools Improve
Generate and Select Solutions
Brainstorming
Deign Solutions
Cost-Benefit Analysis
ROI
Prioritize and Select Solutions
Pilot Solutions
Implementing Solutions
A3 Report
Step Tools
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Control Phase – Steps & Tools Develop Control
Develop Control Plan
Apply Statistical Process Control
Transfer Required Tools to Process Owners
Perform Financial Evaluation and Audit
Step Tools
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How is DMAIC Different
DMAIC
Comprehensive
Project Based
Cohesive Process BasedQuantitative
Stakeholder improvement
Customer Centric
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Six Sigma Certification MASTER BLACK BELT
BLACK BELT
GREEN BELT
YELLOW BELT
WHITE BELT
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Six Sigma Roles Executive Management / Sponsors
MASTER BLACK BELT
BLACK BELT
GREEN BELT
YELLOW BELT
WHITE BELT
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RecapSix Sigma :
Improves the underlying business process Is Customer focused Uses statistical tools
DMAIC is Six Sigma Methodology with following phases : Define Measure Analyze Improve Control
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Thank you for attending this e-learning module.For any questions , queries and help – join us on the
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