Transcript Managing Quality Integrating the Supply Chain S. Thomas Foster

Managing Quality
Integrating the Supply Chain
S. Thomas Foster
Chapter 14
Six-Sigma Management and Tools
© 2007 Pearson Education
14- 1
Strategic Quality Planning
Six-Sigma Management and Tools
Chapter 14
What
is Six-Sigma?
Organizing Six-Sigma
DMAIC overview
DMAIC phases
The Taguchi method
Design for Six-Sigma
Using Six-Sigma from a contingency
perspective
© 2007 Pearson Education
14- 2
Strategic Quality Planning
Six-Sigma Management and Tools
What is Six-Sigma
Sigma () is a greek letter used to
designate a standard deviation (SD) in
statistics
Six refers to the number of SD’s from the
specialized limit to the mean.
Six-Sigma: about 0.5% of products will
not meet specification
© 2007 Pearson Education
14- 3
Strategic Quality Planning
Six-Sigma Management and Tools
What is Six-Sigma
Sigma Level
1
2
3
4
5
6
Long-term ppm* defects
691,462
308,538
66,807
6,210
233
3.4
* ppm = Parts Per Million
© 2007 Pearson Education
14- 4
Strategic Quality Planning
Six-Sigma Management and Tools
What is Six-Sigma
Six-Sigma is … designed to handle
the most difficult quality problems.
% Quality Problems Techniques
90%
Basic tools of Quality
< 10%
Six-Sigma
< 1%
Outside specialists
© 2007 Pearson Education
14- 5
Strategic Quality Planning
Six-Sigma Management and Tools
Organizing Six-Sigma
The
key players
Champion.
Work with black belts to identify
possible projects
Master Black Belts. Work with and train new
black belts
Black Belts. Committed full time to
completing cost-reduction projects
Green Belts. Trained in basic quality tools
© 2007 Pearson Education
14- 6
Strategic Quality Planning
Six-Sigma Management and Tools
Organizing Six-Sigma
In a company with 100 employees there
might be:
One black belt
Sixty green belts
Some companies have yellow belts,
employees familiar with improvement
processes
© 2007 Pearson Education
14- 7
Strategic Quality Planning
Six-Sigma Management and Tools
DMAIC Overview
Stands
for:
Define
Measure
Analyze
Improve
Control
© 2007 Pearson Education
14- 8
Strategic Quality Planning
Six-Sigma Management and Tools
DMAIC Phases

Define

Four Phases:
1.
2.
3.
4.
Develop the business case
Project evaluation
Pareto analysis
Project definition
© 2007 Pearson Education
14- 9
Strategic Quality Planning
Six-Sigma Management and Tools
DMAIC Phases

Define

Developing the Business Case:
1.
2.
3.
Identify a group of possible projects
Writing the business case
Stratifying the business case into
problem statement and objective
statement
© 2007 Pearson Education
14- 10
Strategic Quality Planning
Six-Sigma Management and Tools
DMAIC Phases

Define

RUMBA is used to check the efficacy
of the business case
1.
2.
3.
4.
5.
Realistic
Understandable
Measurable
Believable
Actionable
© 2007 Pearson Education
14- 11
Strategic Quality Planning
Six-Sigma Management and Tools
DMAIC Phases

Measure

Two major steps:
1.
2.
Select process outcomes
Verifying measurements
© 2007 Pearson Education
14- 12
Strategic Quality Planning
Six-Sigma Management and Tools
DMAIC Phases

Measure

Two major steps:
1.

Select process outcomes
Tools Used:
 Process may
 XY matrix
 FMEA
 Gauge R&R
 Capability Assessment.
© 2007 Pearson Education
14- 13
Strategic Quality Planning
Six-Sigma Management and Tools
DMAIC Phases

Measure

Two major steps:
2.

Verifying measurements
Tools Used:
 Use gauges, calipers and other
tools.
 Management System Analysis
(MSA) is used to determine if
measurements are consistent
© 2007 Pearson Education
14- 14
Strategic Quality Planning
Six-Sigma Management and Tools
DMAIC Phases

Measure

Two major steps:
2.

Verifying measurements
Gauge R&R
 Most commonly used MSA
 Determine the accuracy and
precision of your measurements
© 2007 Pearson Education
14- 15
Strategic Quality Planning
Six-Sigma Management and Tools
DMAIC Phases

Analyze

Three major steps:
1.
2.
3.
Define your performance
objectives (X’s)
Identify independent variables
Analyze sources of variability
© 2007 Pearson Education
14- 16
Strategic Quality Planning
Six-Sigma Management and Tools
DMAIC Phases

Analyze

Three major steps:
1.
Define your performance
objectives (X’s)
Identify the independent variables
where data will be gathered
Process maps, XY matrices
brainstorming and FMEA’s are the
tools used
© 2007 Pearson Education
14- 17
Strategic Quality Planning
Six-Sigma Management and Tools
DMAIC Phases

Analyze

Three major steps:
1.
Analyze sources of variability
Use visual and statistical tools to
better understand the relationships
between dependent and
independent variables
© 2007 Pearson Education
14- 18
Strategic Quality Planning
Six-Sigma Management and Tools
DMAIC Phases

Improve

Off-line experimentation


ANOVA
Taguchi
© 2007 Pearson Education
14- 19
Strategic Quality Planning
Six-Sigma Management and Tools
DMAIC Phases

Control

Manage the improved processes using
control charts
© 2007 Pearson Education
14- 20
Strategic Quality Planning
Six-Sigma Management and Tools
The Taguchi method

Design of Experiment (DOE)

Robust design - designed so
that they are inherently defect
free
 Concept Design
 Parameter Design
 Tolerance Design
© 2007 Pearson Education
14- 21
Strategic Quality Planning
Six-Sigma Management and Tools
The Taguchi method

The Taguchi Method provides:
1.
A basis for determining the
functional relationship between
controllable factors
© 2007 Pearson Education
14- 22
Strategic Quality Planning
Six-Sigma Management and Tools
The Taguchi method

The Taguchi Method provides:
2.
A basis for determining the
functional relationship between
controllable factors
© 2007 Pearson Education
14- 23
Strategic Quality Planning
Six-Sigma Management and Tools
The Taguchi method

The Taguchi Method provides:
3.
A procedure for examining the
relationship between random noise
… and product or service
variability
© 2007 Pearson Education
14- 24
Strategic Quality Planning
Six-Sigma Management and Tools
The Taguchi method

Design of Experiment (DOE)

Robust design - designed so
that they are inherently defect
free
 Concept Design - examining
competing technologies
© 2007 Pearson Education
14- 25
Strategic Quality Planning
Six-Sigma Management and Tools
The Taguchi method

The Taguchi Process
1.
2.
3.
4.
5.
6.
Problem identification
Brainstorming session
Experimental design
Experimentation
Analysis
Confirming experiment
© 2007 Pearson Education
14- 26
Strategic Quality Planning
Six-Sigma Management and Tools
Design for Six-Sigma (DFSS)

Used in designing new
products with high
performance

Instead of DMAIC
1. DMADV
2. IDOV
© 2007 Pearson Education
14- 27
Strategic Quality Planning
Six-Sigma Management and Tools
Design for Six-Sigma (DFSS)

Used in designing new
products with high
performance

DMADV
1.
2.
3.
4.
5.
Design
Measure
Analyze
Design
Verify
© 2007 Pearson Education
14- 28
Strategic Quality Planning
Six-Sigma Management and Tools
Design for Six-Sigma (DFSS)

Used in designing new
products with high
performance

IDOV
1.
2.
3.
4.
Identify
Design
Optimize
Verity
© 2007 Pearson Education
14- 29
Strategic Quality Planning
Six-Sigma Management and Tools
failure Six-Sigma from a Contingency Perspective

Reasons for Six-Sigma failure:
1.
2.
3.
Lack of leadership by
champions
Misunderstood roles and
responsibility
Lack of appropriate culture for
improvement
© 2007 Pearson Education
14- 30
Strategic Quality Planning
Six-Sigma Management and Tools
failure Six-Sigma from a Contingency Perspective

Reasons for Six-Sigma failure:
4.
5.
6.
Resistance to change and the
Six-Sigma structure
Faulty strategies for deployment
Lack of data
© 2007 Pearson Education
14- 31
Strategic Quality Planning
Six-Sigma Management and Tools
Summary


The process for Six-Sigma is
define, measure, analyze,
improve and control
Keys to Six-Sigma success
are skilled management,
leadership and long-term
commitment
© 2007 Pearson Education
14- 32