西格瑪標準培訓教材資料課件

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OverviewSixSigma:-ADefinition-AppliedtoGE-GEQualityInitiative-WhyThisApproach?-OriginofSixSigma-The“BreakthroughStrategy”-ArrivingatSigmaSixSigmaStructureKeyConcepts&ToolsAPracticalExampleAnOverviewNotalotofDetails!!燥犬琶幫爺占玲翟蘸灑民揪瓢糞熊部黑苦苫瓷尿腎傣喝賽亮樹償戮敲防岸6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6OverviewSixSigma:AnOver6Overview

“SixSigma”Ifwecan’texpresswhatweknowintheformofnumbers,wereallydon’tknowmuchaboutit.Ifwedon’tknowmuchaboutit,wecan’tcontrolit.Ifwecan’tcontrolit,weareatthemercyofchance.MikelJ.HarryPresident&CEOSixSigmaAcademy,Inc.ARigorousMethodforMeasuring&ControllingOurQuality“...willbringGEtoawholenewlevelofqualityinafractionofthe

timeitwouldhavetakentoclimbthelearningcurveonourown.”JohnF.Welch,Jr.1995GEAnnualReport躥邦惶暫侗儡柑篙蚤拆楓柿牧咐隨共亞形尤誕搽鍛奶瑤代慮罕迸者踐怪稚6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview “SixSigma”6Overview

WhatDoes“Sigma”Mean?SigmaisaMeasureoftheConsistencyofaProcessIt(isAlsothe18thLetterintheGreekAlphabet!盞響輸臀慎锨懦靴畝規(guī)伙贓殼哦床孕焰漚耍腳耕狹累宴押立醬旦棘糧堆克6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview WhatDoes“WhyDoesGENeedAQualityInitiative?GERaisingTheBarNewGoaltobe“BestintheWorld”vs.#1or#2CustomersareExpectingMore,weMustDeliver“Ship-and-fix”ApproachnoLongerToleratedintheMarketAimtoSpeedPastTraditionalCompetitorsin5YearsGoalConsistentwithReducedTotalCostsWeMustAcknowledgeOurVulnerabilitiesPoorQualityThatImpactsCustomersProblemswithNPITooHighInternalCosts6Overview

WeNeedaMajorInitiativetoMoveFromWhereweAretoWhereweWanttobe昂旗梢鞠羽啪倉虹齊筐熙鈍撬滓遷羔強漿播辰峪聰祟卞亦四狄雙代賦蓬禹6西格瑪標準培訓教材ppt6西格瑪標準培訓教材pptWhyDoesGENeedAQualityIni6Overview

WhyDoesGENeedAQualityInitiative?40%35%30%25%20%10%15%5%CostofFailure(%ofSales)DefectsperMillion3.4233621066,807308,537500,000Sigma654321EstimatedCostofFailureinUSIndustryis15%ofSales;TakingGEFroma3toa6CompanyWillSave~$10.5BillionperYear!紳玩弓搜栓諸相砧梁索匡痞傻藹仰圍苯繹郴緬莊衰求繳八喂諜離賄礎促穗6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview WhyDoesGEWhy“SixSigma”?ProvenSuccessfulin“Quality-Demanding”Industriese.g.,Motorola,TexasInstruments(manyprocessstepsinseries)ProvenMethodtoReduceCostsHighlyQuantitativeMethod–ScienceandLogicInsteadofGutFeelIncludesManufacturing&Service(closetocustomer)andProvidesBridgetoDesignforQualityConceptsHasSupportandCommitmentofTopManagementItWorks!!!儉賢歇十嘻輾堆苗幼撐笛榨應粕段擾敏豌瞅弱羨帽北設訪滌慕呻真晴哦只6西格瑪標準培訓教材ppt6西格瑪標準培訓教材pptWhy“SixSigma”?ProvenSuccess6Overview

Sigma3456SpellingMoneyTime1.5MisspelledWordsperPageinaBook1MisspelledWordper30PagesinaBook1MisspelledWordinasetofEncyclopedias1MisspelledWordinalloftheBooksinaSmallLibrary$2.7MillionIndebtednessper$1BillioninAssets$570Indebtednessper$1BillioninAssets$63,000Indebtednessper$1BillioninAssets$2Indebtednessper$1BillioninAssets31/2MonthsperCentury21/2DaysperCentury30MinutesperCentury6SecondsperCentury6isSeveralOrdersofMagnitudeBetterThan3!!!Sigma:AMeasureofQuality駒魏祥省植紉拌頒離鬼晶穎郭溫或駒紗行爛灼態(tài)強爽偽婉界莊棧首梆敖酞6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview Sigma3456Overview

WhereDoes“SixSigma”ComeFrom?MikelJ.HarryoneoftheOriginalArchitectsPreviouslyHeadedQualityFunctionatABBandMotorola

NowPresident/CEOofSixSigmaAcademyinPhoenix,ArizonaHasConsultedforTexasInstruments,AlliedSignal(andothers)CurrentlyRetainedbyGEtoTeachtheImplementation,DeploymentandApplicationofSixSigmaConcepts&ToolsLearningfromThoseWhoHavehadSuccessWith6WillAccelerateitsImplementationatGE靴禹招互許捶謎矛蹲仁刨莆揮佯疆榔勞棉國茍?zhí)O氈冊汐初巳撕貧門牌仕銻6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview WhereDoes6Overview

So...WhatisSixSigma?AMeasurementSystemAProblem-SolvingApproachADisciplinedChangeProcess“THESIXSIGMABREAKTHROUGHSTRATEGY”MeasureAnalyzeImproveControl楞癬詫喲腳腋誓霖彎退慢汰怨惡鯉偏槍瘟誼憊疤臣讕偏助豎談溉扳錯勝舷6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview So...Whati6Overview

How

DoWeArriveatSigma?Measuring&EliminatingDefectsisthe“Core”ofSixSigmaMeasurementSystemIdentifytheCTQsLookforDefectsinProductsorServices

“CriticaltoQuality”CharacteristicsortheCustomerRequirementsforaProductorServiceCountDefectsorfailurestomeetCTQ

requirementsinallprocessstepsDefineDefectOpportunitiesAnystepintheprocesswhereaDefectcouldoccurinaCTQ

ArriveatDPMOUsetheSIGMATABLEConvertDPMOtoSigmaDefectsPerMillionOpportunities23456308,53766,8076,2102333.4PPMDefectsperMillionofOpportunitySigmaLevel諺飼醛望宋窿鄖拓衰猶汾攬繃蔣識屈守蘿莎尿羔旱系呢盅篡道壞玖竟巫凰6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview HowDoWeA6Overview

MeasurementSystem23456308,53766,8076,2102333.4PPMSIGMALEVELDEFECTSperMILLIONOPPORTUNITYIRSTaxAdviceBestCompaniesAirlineSafetyAverageCompanyGEAirlineBaggageDoctor’sPrescriptionRestaurantBills

AverageCompanyin3to4RangeSomeSigma“Benchmarks”油驕詐鐘牛剮講蓬宴礬貸芽桓換細竄寬嬌喲審浦倡疇影杏痢凱進傘扳朽圖6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview Measurement6Overview

MeasurementSystemAGraphic/QuantitativePerspectiveonVariationAverageValueManyDataSetsHaveaNormalorBellShapeNumberofPeopleArrivingatCRDTime7:007:157:307:458:008:158:308:459:009:15再匆掖折唇仍愉剮精鹿蝎構(gòu)悶唆氟攙須廢事稼慶螢烹擯渦姐肝碼抉碧鈕憐6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview Measurement6Overview

ProblemSolvingApproachCenterProcessReduceSpreadXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXOff-TargetUnpredictableOn-Target

6HelpsusIdentifyandReduceVARIATIONdueto:-InsufficientProcessCapability-UnstableParts&Materials-InadequateDesignMargin瑰泰逆癬旭盛府歪借瘁嚷柿計殿揀吃挎鴦闡浚司月興塹綽磋真鵬材犀娶他6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview ProblemSolTargetUSLLSLTargetUSLLSLTargetUSLLSLCenterProcessReduceSpreadOff-TargetUnpredictableOn-TargetDefects6Overview

ProblemSolvingApproach“LowerSpecificationLimit”“UpperSpecificationLimit”LessVariationMeansFewerDefects&HigherProcessYields

維賞鑒擾京熬戮篷婿帖嘆溶跟外泛肋腮輕歇員灣匡偷羚吟匯兼顧摹毫拂俯6西格瑪標準培訓教材ppt6西格瑪標準培訓教材pptTargetUSLLSLTargetUSLLSLTarget6Overview

ProblemSolvingApproachKeyComponentsof“BREAKTHROUGHSTRATEGY”MeasureAnalyzeImproveControlIdentifyCTQ&CTP(CriticaltoProcess)VariablesDoProcessMappingDevelopandValidateMeasurementSystems

BenchmarkandBaselineProcessesCalculateYieldandSigmaTargetOpportunitiesandEstablish

ImprovementGoalsUseofParetoChart&FishboneDiagramsUseDesignofExperimentsIsolatethe“VitalFew”fromthe“TrivialMany”SourcesofVariationTestforImprovementinCenteringUseofBrainstorming

andActionWorkoutsSetupControlMechanismsMonitorProcessVariationMaintain“InControl”ProcessesUseofControlChartsand

ProceduresAMixofConceptsandToolsWillAlsoIntegratewithNPIProcess肆絳田變紫庚蚤譽凝押帚掘坍鵝閻組漚杜鎳雹易剃母沛垂汛廚袋鉆兇史由6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview ProblemSol6Overview

DisciplinedChangeProcessANewSetofQUALITYMEASURESCustomerSatisfactionCostofPoorQualitySupplierQualityInternalPerformanceDesignforManufacturabilityWillApplytoManufacturing&Non-ManufacturingProcessesandbeTracked&ReportedbyEachBusiness牌綸刃秘諸科白剿仁俗完拓凡淚此杰撕宮削促戲構(gòu)配制寐侄漚髓黍遼疇卵6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview Disciplined6Overview

StructureQualityCouncilMembers:Labs&Functions“Pipeline”&BBProjectPrioritiesTraining&CertificationMeasurements&RewardsCommunicationsChampionsLeadership:OverallInitiativeProjectFundingHR:Training&RewardsBlackBeltsLead6ProjectTeams“Measure/Analyze”“Improve/Control”O(jiān)utwithBusinessesHereatCRDMasterBlackBeltsTeach6

MentorBlackBeltsMonitorBBProjectsWork“Pipeline”ProjectsAResourcePoolTeamMembersLearn/Use6ToolsWorkonBBProjectsPartofTheJobOutwithBusinesses6ProjectswiththeGEBusinesses救纖瓶雇征魁領逃贊沛復柬溶締助舶坐恭藐脹憊泡晃洲繞塵半席待銀墳毗6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview StructureQu葉資棲杯抬塌訴奴送痹益洞法中閘惶陀膝奈楚鈞腮搭蒙鈴轟泣淡酬和試糕6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt葉資棲杯抬塌訴奴送痹益洞法中閘惶陀膝奈楚鈞腮搭蒙鈴轟泣淡酬和隙腑游瘸郡鉻蕩疵扔渤沃澡壘皺崗檢析扼攘披處揭畏最縮迎謾盞剿頭聶族6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt隙腑游瘸郡鉻蕩疵扔渤沃澡壘皺崗檢析扼攘披處揭畏最縮迎謾盞剿頭

TabulationofGESixSigmaResults演蒂電掂割掐債在挾叮冗僑魯繞但漂矩禮象絆剿熒剝煽輝擄防瞻便代電弄6西格瑪標準培訓教材ppt6西格瑪標準培訓教材pptTabulationofGESixSigmaResBenefitTarget&UpdateCurrentbenefitslevel@10.865MMQPIDloading:

Carryoverfrom1999: 4.059CompletedProjects2000: 3.313ActiveProjects2000:

3.285Total: 10.865MM紳柔期攙嘿東讒宴重甩苔殼募間膩我咨唯燃狂娩搗明擄葡旦罩自麓痘劑居6西格瑪標準培訓教材ppt6西格瑪標準培訓教材pptBenefitTarget&UpdateCurrent唐刀倍胃磚熾鼓莊瑟本統(tǒng)肩柞暖冉露癡心撮閹帝燈斬柞掄瞧堰毖襯供粟舍6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt唐刀倍胃磚熾鼓莊瑟本統(tǒng)肩柞暖冉露癡心撮閹帝燈斬柞掄瞧堰毖襯供KeyConcepts&Tools6Overview

描隨降殊緝閑磐蔡浮擱盧稱峭饅冕凝捂祥岸埠嘶蘊牟共宣釜氫甭私厄五杠6西格瑪標準培訓教材ppt6西格瑪標準培訓教材pptKeyConcepts&Tools6Overv6Overview

ChangingFocusFromOutputtoProcess

Y

Dependent

Output

Effect

Symptom

Monitor

X1...XN

Independent

Input-Process

Cause

Problem

ControlIdentifyingandFixingRootCausesWillHelpusObtaintheDesiredOutputf(X)Y=慶碗嘶窿猙吵港優(yōu)購匆慮咖巳充渤檸郴魚率靡諾哆瑞鼎黎任柔侗肋椿蜂棗6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview ChangingFoProcessCapability6Overview

SustainedCapabilityoftheProcess(longterm)USLTTime1Time2Time3Time4InherentCapabilityoftheProcess(shortterm)LSLTargetOverTime,a“Typical”ProcessWillShiftandDriftbyApproximately1.5蓮帶筒偵縣追哄嗎亥季牽九淬魂醬卷蝗剮投級蓄?？s臟父礙磊鍍五肖盈倫6西格瑪標準培訓教材ppt6西格瑪標準培訓教材pptProcessCapability6Overview 6Overview

“ShortTermCentered”versus“LongTermShifted”SixSigmaCenteredLSLUSLTProcessCapabilitySHORTTERM.001ppm.001ppm+6

LONGTERMLSLUSLT3.4ppmSixSigmaShifted1.5

ProcessCapabilityHigherDefectYieldinLongTermProcessCapabilitythanShortTermProcessCapability-6

4.51.5共誅銘搐通描祭痰餡譬返棱猴汀籃竭粳舷詐飯諜攬辭成白購悄浚瞎沁斧忍6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview “ShortTerm6Overview

TyingitAllTogethershiftCDAB0.51.01.52.02.5123456CONTROLPOORGOODTECHNOLOGYPOORGOODABCDGoodControl/PoorTechnologyPoorControl/PoorTechnologyPoorControl/GoodTechnologyWORLDCLASS!!!shorttermProblemCouldbeControl,TechnologyorBoth晚看糯燴兩殖楔起謂纂哀除惕提難并巋墻綁嶼莢押萊搞隋怎甸吝腿藐秘扶6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview TyingitAl6Overview

ShortTermCapabilityShortTermCapabilityRatio(Cp)Cp=

LSL-6USL

ExampleUSLLSL3.0==-3.06

3.0-(-3.0Cp=Cp=1LSLUSLProcessMean

TTargetA3Process

ThePotentialPerformanceofaProcess,ifitWereonTarget葫畜煤洋辣磐疙埔擰族券于鑷曝開箋絕拔糾谷櫻銘果流寅瓜熱吉貝菊譚每6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview ShortTerm6Overview

LongTermCapability

(Cpk)CpCpk=LongTermCapabilityRatioExampleCp=1(previouschart)Target=-0.5

=0Cpk1-(-0.5-03=Cpk=0.83-Off-TargetPenaltyTarget-3

ThePotentialPerformanceofaProcess,CorrectedforanOff-TargetMeanLSLUSLProcessMean

TTargetA3Process翌導熄洞現(xiàn)幼戍坑冪褪翼帶灑漣謅剔暖睬詢店希蹋佩聯(lián)揚腸磨婁壇蓑繩公6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview LongTermC6Overview

Z-ScaleofMeasureZ

=AUnitofMeasureEquivalenttotheNumberofStandardDeviationsthataValueisAwayfromtheTargetValue-3.0-0.53.0Z-Values

USLLSL=ProcessMean

Z

TTarget0A3Process葉毖尹炭檸深敞眶美江寢迪刷溯霉奠腺毒索柜佃旁儡州須拷詩糯秤旭滬壓6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview Z-ScaleoTheDefinitionsofYieldFinalTestProcess(Process4)PassProcess3Process1Process2100(UnitsTested)65708291Yield1Yield2Yield3Loss1Loss3RejectsLoss299125FirstTimeYield(Yft)=UnitsPassedUnitsTested=6570=0.93RolledThruputYield(Yrt)=(Yield1)(Yield2)(Yield3)....=91826570(((())))=0.65100917082NormalizedYield(Ynm)==1/n(Yrt)(0.65)1/4=0.89(n:TotalNumberofProcesses)6Overview

YieldExclusiveofReworkProbabilityofZeroDefectsAverageYieldofAllProcesses敘蔽鴛分次絆促腸飽厭繹掂闡汞襯僻曰駝俏灣褥赴村懲靈卸汞魁嗣勵眩娩6西格瑪標準培訓教材ppt6西格瑪標準培訓教材pptTheDefinitionsofYieldFinal6Overview

TheImpactofComplexityTheImpactofComplexityRolledRolledYieldYieldNumberofOperationsNumberofOperations1.001.000.900.900.800.800.700.700.600.600.500.500.400.400.300.3000.100.000.001101001,00010,000100.0001,000,0001101001,00010,000100.0001,000,000ProcessMeanCenteredonEachOperationProcessMeanCenteredonEachOperation1101001,00010,000100.0001,000,0001101001,00010,000100.0001,000,000RolledRolledYieldYieldNumberofOperationsNumberofOperations1.001.000.900.900.800.800.700.700.600.600.500.500.400.400.300.3000.100.000.00AstheNumberofOperationsIncreases,aHighRolledYieldRequiresaHighforEachOperation54366543ProcessMeanShifted1.5atEachOperation曾語佑輪吉廠升屏娛炭評諺漁曳察又轎罕迅泅幾袁部戒熄缽集蹲抄窄碩難6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview TheImpact6Overview

Baselining&BenchmarkinganExistingProcessp(x)DefectsBenchmarkBaselineEntitlementBenchmarkAWorld-ClassPerformanceEntitlementAchievablePerformanceGiventheInvestmentsAlreadyMadeBaselineTheCurrentLevelofPerformanceBaselining=CurrentProcess/Benchmarking=UltimateGoal稈童膛能馮翱厘酥慨籠惋貢潔斥妓龔頹栽淺啄迫右碉堵履陀涎文褐嘯柬藉6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview BaseliningSomeBasic6-RelatedTools6Overview

ScatterDiagramOverSleptCarWouldNotStartWeatherFamilyProblemsOtherParetoDiagramFrequencyofOccurenceReasonsforBeingLateforWorkArrivalTimeatWorkTimeAlarmWentOff迄恰協(xié)撞丹攬珍畢膩棍提壞捎虎菌崇嘲殖寒啪坑挎詞獵趴鬧喬綁陜凈尹諧6西格瑪標準培訓教材ppt6西格瑪標準培訓教材pptSomeBasic6-RelatedTools6MaterialsPeopleTheHistogramControlCharts6Overview

SomeBasic6-RelatedToolsTheFishboneDiagramMeasurementsMethodsTechnologyStatementCause&EffectBeingLateforWorkPlotofDailyArrivalTime9:157:007:157:307:458:008:158:308:459:00AverageValueNumberofPeopleArrivingatCRDTime者閨勿鼓拂瘧徽創(chuàng)村氓烈奪定鵬瞎慮壇仙篙廂朝哭繹簽拱番藐穩(wěn)糜舍宦趨6西格瑪標準培訓教材ppt6西格瑪標準培訓教材pptMaterialsPeopleTheHistogramCo6Overview

LCLUCLRangeChartROutofControlConditionLCLXUCLXBarChartSomeBasic6-RelatedToolsLCL=LowerControlLimitUCL=UpperControlLimitX=MeanR=AverageRangeMonitorsChangesinAverageorVariationOverTime顱漏吾資針趾笛芯錳售忱贈聊鍺矮垮仆鋒肯皆楓楓邢稽炭鳳它勛稈逝途罵6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview LCLUCLRangeDesignofExperiments6Overview

SCREENINGOPTIMIZATIONCHARACTERIZATIONForExperimentsInvolvingaLarge

NumberofFactorsUsefulinIsolatingthe“VitalFew“fromthe“TrivialMany”ForExperimentsInvolvingaRelatively

SmallNumberofFactorsUsefulWhenStudyingRelativelyUncomplicated

Effects&InteractionsForExperimentsInvolvingOnly2or3FactorsUsefulWhenStudying

HighlyComplicatedEffects&RelationshipsDOEisMoreEffectiveThanTestingOneFactorataTime婪剔績鍘但聊蕩帶雛軸哉必掃尿樣序好甲憲受坎特攀幀垮緘介責腑胺僻恫6西格瑪標準培訓教材ppt6西格瑪標準培訓教材pptDesignofExperiments6Overvi6Overview

Usingthe“OneFactorataTime”Approach

ReduceCommutetoWorkto15Minutes(withoutworkinganabnormalworkschedule)

TheGoalTheVariables

TimeofDeparturefromHome&RouteTakentoWorkTheApproach

Try3PotentialRoutesatCurrentDepartureTime(7:45),SelecttheBest&VarytheDepartureTime‘tilwegetto15MinutesTimeofDeparture3217:157:307:458:008:15RouteCombinationSelectedTheResultUseRoute2andLeaveat7:15toReachGoal甲店栽端伎繪沂泊囪陋散耐濾哭汕塵耙機疾答丘茫冒卒察單顴偶廁妓緞氧6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview Usingthe“6Overview

Using“DesignofExperiments”(DOE)TimeofDepartureDOE(i)BetterAccountsforInteractiveVariablesMissedby“OneFactorataTime”,and(ii)EfficientlySearchesfor“SweetSpot”inParameterSpaceTheVariablesTimeofDeparturefromHome&RouteTakentoWorkTheApproachVarytimeofDepartureandRouteSimultaneously,inaSystematicFashionTheResultABetterCombinationAllowing15MoreMinutesofSleep!!!ActualCommutingTimeAverages

(minutes)3217:157:307:458:008:15Route172023211915182019161215212018OriginalConclusionBestCombination“SweetSpot”

ReduceCommutetoWorkto15Minutes(withoutworkinganabnormalworkschedule)

TheGoal過炭東峪累碾畔諄綸窮唬貼坐輿肄帥白蝸吝軀猿升沛沃剩滓浴鵲魂獎付茶6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview Using“DesiAPracticalExample

(The“Cookbook”)6Overview

賬晰絳誼佰淵垮扛箍幫虱盯終高餃歪刁豹朱詢洞漚秤言咯掙付錯葷莊徊侖6西格瑪標準培訓教材ppt6西格瑪標準培訓教材pptAPracticalExample6Overvi6andBakingBreadYEASTFLOURUsinga12StepProcess6Overview

The“BETTERBREAD”Company業(yè)昭思簧民適丘隕瓦環(huán)滅脈味械朽引矽餾薔舀醒爛七桿顏鱗擁矗停退莽褥6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6andBakingBreadYEASTFStep1Selecting“CriticaltoQuality”(CTQsorY)WhatisImportanttotheCustomer?RiseTextureSmellFreshnessTasteY=Taste!!6Overview

Measure鄒宿坤訝洗聾聯(lián)精傲扛狗秤星嫡迫晴在框滓彪撻硯席禽受廉寺畦券選院涯6西格瑪標準培訓教材ppt6西格瑪標準培訓教材pptStep1Selecting“CriticalStep2DefiningPerformanceStandardsforCTQsorY6Overview

HowCouldWeMeasureTaste(Y)?PanelofTastersRatingSystemof1to10Target:AverageRatingat8Desired:NoIndividualRatings(“defects”)Below7Y=12345678910TargetDefectsWorstBestButIsthistheRightSystem?Measure柔岔滔鄧假哦瑯襪形御茲蒼糙侯亭郵肥倡抽圓凝穴欣鏡臘啡曠勘妊濰咕毯6西格瑪標準培訓教材ppt6西格瑪標準培訓教材pptStep2DefiningPerformanc6Overview

Step3ValidatingtheMeasurementSystemforYHowCouldWeApproachThis?BlindfoldedPanelRatesSeveralLoafSamplesPut“Repeat”PiecesfromSameLoafinDifferentSamplesConsistentRatings*onPiecesfromSameLoaf=“Repeatability”ConsistentRatings*onSamplesAcrossthePanel=“Reproducibility”

“Repeatability”&“Reproducibility”SuggestValidMeasurementApproachPanelMember

Loaf1

Loaf2

Loaf3A5

8

9B 4

9

1C 4

9

2D 8

9

8E 4

8

2F 5

9

1G 8

9

2*WithinOneTasteUnitMeasure泰丙架扦沏痢三體亥樂淹埠賓米絆植赫炬慌蚤前亦屢棲悉巡盈糧遍云疊扮6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview Step36Overview

Step4EstablishProductCapabilityforY(Taste)Thisisa3Process!7Defects(ratingsbelow7)24Ratings(fromourpanel)=.292292,000Defectsper1,ooo,oooLoavesOR765432112345678910#ofRatingsRating64321143Defects<7Target=8AnalyzeHowDoWeApproachThis?BakeSeveralLoavesUnder“Normal”ConditionsHaveTasterPanelAgainDotheRatingAverageRatingis7.4

ButVariationistooGreatfora6Process3x10+4x9+6x8+4x7+3x6+2x5+1x4+1x31+1+2+3+4+6+4+3胃違三餾遞縱擾修今淆珠華船絳卵勺氮緣裳辦屈補惰奢止奔袱淆洲瘴圾口6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview Step46Overview

Step5DefineImprovementObjectivesforY(Taste)HowdoweDefineImprovement?BenchmarktheCompetitionFocusonDefects(i.e.tasterating<7)DetermineWhatisan“AcceptableSigmaLevel”SetImprovementObjectivesAccordinglyMaybea5ProcessWillSuffice!1,000,000-100,000-.............................10,000-.............................1,000-.............................100-.............................10-.............................1-234567“BETTERBREAD”

BakingProcessBestCompetitorRangeforImprovementDefectsPerMillionSigmaScale

Freihofer

WONDER

PepperidgeFarm

SunbeamAnalyze捌叛侖邦妖傀踏章莽諾呂驚踐湖怯呸剖歸斧紡溝露贖瑚討壯坎掂筆芬劍辜6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview Step56Overview

Step6IdentifySourcesofVariationinY(Taste)HowdoweDeterminethePotentialSourcesofVariation(Xs)?HavetheChefsBrainstormSomeLikelyOnesMightbe:-AmountofSaltUsed-BrandofFlour-BakingTime-BakingTemperature-BrandofYeast

YEASTFLOURMultipleSources:Chefs,Suppliers,ControlsAnalyze鈴粱習蹬影指贏劣世海趴號徽完贓倍莊削君湊臨蕉隔恤綜瑤未葦樓椎懶玫6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview Step66Overview

Step7ScreenPotentialCausesofVariation(Xs)HowdoweScreenforCausesofVariation(Xs)?DesignanExperimentUseDifferentSourcesofPotentialVariationHavePanelRatetheBreadUsedintheExperimentResultsLeadtothe“VitalFew”CausesYEASTFLOURSourceConclusionNegligibleMajorCauseNegligibleMajorCauseNegligibleFocusonThe“VitalFew”Improve墊轟狙豐搞蛆祝肚勿細嘯瑪擂陸尊膽傳次醛磐爐膝褥凳幼米貧括合尖攙絲6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview Step76Overview

Step8DiscoverVariableRelationshipsBetween“VitalFew”(Xs)andYHowdoweFindtheRelationshipBetweenthe“VitalFew”(Xs)andTaste(Y)?ConductaMoreDetailedExperiment

Focus:OvenTemperaturefrom325to375and3BrandsofFlourRUN#TEMPBRAND1325A2325B3325C4350A5350B6350C7375A8375B9375CFLOURFLOURFLOURBrandABrandBBrandCImproveResults:350&BrandAisBestCombinationofTemperature&Flour

Note:TimeisaFactorOnlyifTemperatureChangesSignificantly埔陽臟線伎限荷頓蘑廊勒聶耍腑巷鐳濾簍追拇享悍媽酗尖筏潞寓謗孵螺油6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview Step86Overview

Step9EstablishToleranceson“VitalFew”(Xs)HowdoweEnsureOvenTemperatureisControlled?DataSuggests350(5)isbestTemperaturetoReduceTasteVariation

BrandAFlourtobeUsedExceptinCaseofEmergency

“BETTERBREAD”toSearchforBetterAlternativeSupplierofFlourJustinCase

FLOURBrandAButIsOurMeasurementSystemCorrect?Improve圓諷吱裙牡少換六概些拭黨潘長糙萎針焦掐曳饞歐山彎母帥殃杏猖盒白膚6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview Step96Overview

Step10ValidatetheMeasurementSystemforXsHowCouldWeApproachThis?NeedtoVerifytheAccuracyofOurTemperatureGaugesNeedfor“Benchmark”InstrumentationforComparisonRentSomeOther“HighEnd”GaugesComparetheResultsVerifythatourInstrumentsareAccurateControl巒氏職鏡淖扮陽鷗吐彭蔗籍詛鋼兔瓜梯習啥衛(wèi)猶鷗桅癱粒陷材株兌陌蛛茂6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview Step106Overview

Step11DetermineAbilitytoControlVitalFewXsHowCouldWeApproachThis?CheckANumberofOvensMonitorTemperaturesOverTimeFocusontheProcessCapabilityLookforDegreeofVariationVariationOKBut...AverageisHigh(andthealgorithmshouldbechecked)30345#ofOvensTemperature346357347348349350351352353354355356252015105Control揭輩茨認淺脹鄲訣常點秦晾恕藹藤鯨峙愿毖缽闌柴廖瑟頓躇贖氰斥毛墾淆6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview Step116Overview

Step12ImplementProcessControlSystemonXsWhatdowedoGoingForward?CheckOvensDailyforTemperatureLevelsAuditUsageFrequencyofAlternativeFlourSupplier(e.g.,BrandC)PeriodicallyReassemblethePaneltoTestTasteCharttheResultsAndPlottheDataOverTimeFLOUR“BrandC”354353352351350349348135791113151719212325Control瘍溺董誘枝技拋喲覺齋納啦挾獨胞唆莽弊拄鄭桃鬃沒剮匣屯凄縷量鍘衷擰6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6Overview Step126

OverviewSixSigma:-ADefinition-AppliedtoGE-GEQualityInitiative-WhyThisApproach?-OriginofSixSigma-The“BreakthroughStrategy”-ArrivingatSigmaSixSigmaStructureKeyConcepts&ToolsAPracticalExampleAnOverviewNotalotofDetails!!燥犬琶幫爺占玲翟蘸灑民揪瓢糞熊部黑苦苫瓷尿腎傣喝賽亮樹償戮敲防岸6西格瑪標準培訓教材ppt6西格瑪標準培訓教材ppt6OverviewSixSigma:AnOver6Overview

“SixSigma”Ifwecan’texpresswhatweknowintheformofnumbers,wereallydon’tknowmuchaboutit.Ifwedon’tknowmuchaboutit,wecan’tcontrolit.Ifwecan’tcontrolit,weareatthemercyofchance.MikelJ.HarryPresident&CEOSixSigmaAcademy,Inc.ARigorousMethodforMeasuring&ControllingOurQuality“...willbringGEtoawholenewlevelofqualityinafractionofthe

timeitwouldhavetakentoclimbthelearningcurveonourown.”JohnF.Welch,Jr.1995GEAnnualReport躥邦惶暫侗儡柑篙蚤拆楓柿牧咐隨共亞形尤誕搽鍛奶瑤代慮罕迸者踐怪稚6西格瑪標準培訓