23. Six Sigma 陳妍言 (Stella Chen) 944024 ‧ Black Belt’s Curriculum [ 課程 ] ‧ DMAIC
24. Brief Introduction ‧ “ Six-sigma is all about solving a problem with an unknown solution”, said Peterka ‧ DMAIC is used to improve existing processes
25. Recommended BB Curriculum (Manufacturing Orientation) Break into 5 categories: Define, Measure, Analyze, Improve, Control Context ‧ Why Six Sigma ‧ DMAIC process ‧ Project management fundamentals ‧ Team effectiveness fundamentals
26. Recommended BB Curriculum (Define) ‧ Project selection ‧ Scoping projects ‧ Developing a project plan - Critical to Quality (CTQ) ‧ Process identification (SIPOC)
27. DMAIC - Define SIPOC ‧ Suppliers – who feeds the process ‧ Inputs – what do they feed ‧ Process – steps in the process ‧ Outputs – outputs of the process ‧ Customer – who pulls from the process
28. DMAIC - Define SIPOC ‧ Define (and narrow) the project’s focus ‧ Clarify the results being sought ‧ Establish boundaries and resources for the team ‧ Communicate goals and plans
29. DMAIC – Measure ‧ Determine what to measure and why ‧ Prepare plans to collect output, process and/or input data ‧ Construct forms and test data collection procedures ‧ Examine variation (charts/graphs ) ‧ Baseline sigma performance
30. DMAIC – Measure ‧ Identify Key Measurements (i.e. initial capability and stability ) ‧ Data Collection Plan (input, process, and output indicators) ‧ Data Collection Execution
31. DMAIC – Measure ‧ Document Process Variations (Potential impacts on CTQs) ‧ Establish Performance Baseline (preventative action plans are put into place)
34. DMAIC - Analyze ‧ Eliminate the gap between existing performance and the desired level of performance Estimate improvement targets
35. Recommended BB Curriculum (Improve) ‧ Narrow, screen and select best solution ‧ Solution validated and benefit proposal presented (cost/benefit analysis ) ‧ Solution test ‧ Implementation strategies
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37. Define Project Scope Plan (CTQ) Process Identification (SIPOC) Measure Data Collection Data Testing Baseline Performance Control Standardize Improved Process Monitoring Plan Analyze Determine Root Case Eliminate the Gap Improve Selection the Best Solution Solution Testing Implementation DMAIC Cycle
38. Example Six sigma project - parts failing after final machines Define: Inspection is rejecting a high number of parts after final machines. Measure: Product yield was determined and number of defects in total to establish defect yield. Analyze: Machine operators, engineers and vendor identified variables that could impact the production of defects. Range of acceptable levels determined for each variable. Different Designed Experiments were conducted.
39. Example (cont.) Improve: Operating instructions changed to the conditions with the lowest defect production consistent with capacity limits. Final product yield increased 13%. Control: Control charts installed for each machine. Decision tree corrective action plan provided for known defects and known corrective actions.
40. Reference Pyzdek T.(2003), “The Six sigma project DMAIC cycle”, http://www.pyzdek.com/PDF/DMAIC.pdf Hoerl, R.W.(2001). “Six Sigma Black Belts: What Do They Need to Know?”. Journal of Quality Technology, American Statistical Association, Toronto, Ontario, CA Hoerl, R.W.(2004). “One perspective on the future of Six-Sigma”. Int.J.Six Sigma and Competitive Advantage , Vol.1, No.1, 2004 Eichholz, J(2001). “Using 6 Sigma Methodology and Tools to Design and Implement a Single Source Documentation Process”. http://www.stc.org/confproceed/2001/PDFs/STC48-000070.PDF
