Transcript Managing Quality Integrating the Supply Chain
Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
Chapter 13 Six-Sigma Management and Lean Tools 13- 1
Strategic Quality Planning
Six-Sigma Management and Lean Tools Chapter 13
What is Six-Sigma?
Organizing Lean Six-Sigma DMAIC Overview DMAIC Phases The Taguchi Design of Experiments Design for Six-Sigma Lean Six-Sigma from a Contingency Perspective Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean 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 13- 3 Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
Strategic Quality Planning
Six-Sigma Management and Lean 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
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Strategic Quality Planning
Six-Sigma Management and Lean Tools What is Six-Sigma?
Six-Sigma effectiveness
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Strategic Quality Planning
Six-Sigma Management and Lean 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 Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean 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 Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools Organizing Six-Sigma
Lean-Six Sigma Pull production Value stream map Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools DMAIC Overview
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Strategic Quality Planning
Six-Sigma Management and Lean Tools DMAIC Phases
Define-
selected projects are identified and 1.
2.
3.
4.
Four Phases: Developing the business case Project evaluation Pareto analysis Project definition Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools DMAIC Phases
Define
1.
2.
3.
Developing the Business Case: Identifying a group of possible projects Writing the business case Stratifying the business case into problem statement and objective statements Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools DMAIC Phases
Define 1.
2.
3.
4.
5.
RUMBA is used to check the efficacy of the business case
R
ealistic
U
nderstandable
M
easurable
B
elievable
A
ctionable Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Project Risk and Return Matrix Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Pareto Analysis Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Problem Definition Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools DMAIC Phases
Measure
1.
2.
Two major steps: Selecting process outcomes Verifying measurements Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools DMAIC Phases
Measure
1.
Two major steps: Select process outcomes Tools used: Process map
XY
matrix FMEA Gauge R&R Capability Assessment.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools DMAIC Phases
Process Map
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Strategic Quality Planning
Six-Sigma Management and Lean Tools DMAIC Phases
XY
Matrix
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Strategic Quality Planning
Six-Sigma Management and Lean Tools DMAIC Phases
XY
Matrix for Example 13-3
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Strategic Quality Planning
Six-Sigma Management and Lean Tools DMAIC Phases
Solution for Example 13-3
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Strategic Quality Planning
Six-Sigma Management and Lean Tools DMAIC Phases
Measure
2.
Two major steps: Verifying measurements Tools Used: Use gauges, calipers and other tools.
Management System Analysis (MSA) is used to determine if measurements are consistent Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools DMAIC Phases
Measure
2.
Two major steps: Verifying measurements Gauge R&R Most commonly used MSA Determine the accuracy and precision of your measurements Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools DMAIC Phases
Gauge R&R in Excel
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Strategic Quality Planning
Six-Sigma Management and Lean Tools DMAIC Phases
Analyze
Three major steps: 1.
Define your performance objectives 2.
3.
Identify independent variables (X’s) Analyze sources of variability Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools DMAIC Phases
Analyze
Three major steps: 1.
Define your performance objectives Capability Analysis Identify the independent variables where data will be gathered Process maps, XY matrices brainstorming and FMEA’s are the tools used Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools DMAIC Phases
Capability Analysis
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Strategic Quality Planning
Six-Sigma Management and Lean Tools DMAIC Phases
Analyze
Three major steps: Analyze sources of variability Use visual and statistical tools to better understand the relationships between dependent and independent variables Include histograms, box plots, scatter plots, regression analysis, and hypothesis tests Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools DMAIC Phases
Improve
Off-line experimentation ANOVA Taguchi Method Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools DMAIC Phases
Control
Manage the improved processes using control charts and implementing control plans Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools
The Taguchi Method Design of Experiment (DOE) Robust Design Concept Design Parameter Design Tolerance Design Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools
The Taguchi Method Design of Experiment (DOE) Robust design - designed so that they are inherently defect free Concept Design - examining competing technologies Parameter Design- selection of control factors and the determination of optimal levels for each of the factors Tolerance Design- developing specification limits 13- 34 Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
Strategic Quality Planning
Six-Sigma Management and Lean Tools
The Taguchi Method The Taguchi Method provides: 1.
A basis for determining the functional relationship between controllable design factors and the outcomes of a process Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools
The Taguchi Method The Taguchi Method provides: 2.
A method for adjusting the mean of a process by optimizing controllable variables Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools
The Taguchi Method The Taguchi Method provides: 3.
A procedure for examining the relationship between random noise … and product or service variability Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools
The Taguchi Method Classic QC- Step Function Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools
The Taguchi Method Taguchi Quadratic Loss Function Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools
The Taguchi Method The Taguchi Process Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Example 13-6 Results
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Strategic Quality Planning
Six-Sigma Management and Lean Tools
Design for Six-Sigma (DFSS) Used in designing new products with high performance Instead of DMAIC 1.
DMADV 2.
IDOV Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools
Design for Six-Sigma (DFSS) Used in designing new products with high performance DMADV 1.
Design 2.
Measure 3.
Analyze 4.
Design 5.
Verify Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools
Design for Six-Sigma (DFSS) Used in designing new products with high performance IDOV 1.
Identify 2.
Design 3.
Optimize 4.
Verify Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools
Six-Sigma from a Contingency Perspective 1.
2.
3.
Reasons for Six-Sigma failure: Lack of leadership by champions Misunderstood roles and responsibilities Lack of appropriate culture for improvement Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean Tools
failure Six-Sigma from a Contingency Perspective 4.
5.
6.
Reasons for Six-Sigma failure: Resistance to change and the Six-Sigma structure Faulty strategies for deployment Lack of data Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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Strategic Quality Planning
Six-Sigma Management and Lean 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 Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall.
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