IM 746 Lean Six Sigma

1 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean 6 Sigma - Lecture Handouts
Department of Industrial and Management Engineering
AASTMT
IM 746 Lean Six Sigma IM 746 Lean Six Sigma
Lecture 5
The DMAIC Approach
ANALYZE (b)
1 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean Six Sigma- Lecture Handouts
ANALYZE (b)
Department of Industrial and Management Engineering
AASTMT
IM 746 Lean Six Sigma
DMAIC Process
Control the process,
implement control charts
for key variables, mistake
proof processes and
Define business drivers,
select customer critical
processes, define project and
d l i l t ti l
Define
Measure
Analyze
Improve
Control
evaluate results
Improve and evaluate
solutions, implement
variation reduction,
standardize process and
i k f t
develop implementation plan
Measure key process ,
collect and analyze data,
identify the vital few that have
greatest impact, estimate
2 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean Six Sigma- Lecture Handouts
DMAIC DMAIC = = DDefine, efine, MMeasure, easure, AAnalyze, nalyze, IImprove and mprove and CControl ontrol
assess risk factors
process capability and
measurement system
analysis
Analyze cause and effects, create
Multi-variable analysis, determine
variance components, and assess
correlation
IM 746 Lean Six Sigma
2 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean 6 Sigma - Lecture Handouts
Department of Industrial and Management Engineering
AASTMT
IM 746 Lean Six Sigma
Tools
Cause and effect diagrams
C&E Matrix
Pareto Chart (already covered) Pareto Chart (already covered)
5 Whys analysis
Correlation
Regression analysis
Variation Analysis
3 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean Six Sigma- Lecture Handouts
Department of Industrial and Management Engineering
AASTMT
IM 746 Lean Six Sigma
Causes of Variations
Variations are the differences that occur in
products, services, and processes. There are
two types of variation: two types of variation:
1) Common Causes
2) Special Causes
Adapted from: The Lean Six Sigma Pocket Toolbox: by Michael L. Georgeet al., McGraw-Hill 2005
Type of variation Synonyms
- Chance cause
N i bl
4 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean Six Sigma- Lecture Handouts
Common cause
- Non-assignable cause
- Noise
- Natural pattern
Special cause
- Assignable cause
- Signal
- Un Natural pattern
Source: http://en.wikipedia.org/wiki/Common-cause_and_special-cause (Accessed: 18.12.2010)
IM 746 Lean Six Sigma
3 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean 6 Sigma - Lecture Handouts
Department of Industrial and Management Engineering
AASTMT
IM 746 Lean Six Sigma
Common Causes of Variations
Common causes: the variation due to random
factors that are always present in the process
A process with only common cause variation is A process with only common cause variation is
said to be "in control" . Though random, the
variation will be stable and predictable with a
determined range
An "in control" process may still be unacceptable
because it has too much variation
T d i ti i t h th
5 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean Six Sigma- Lecture Handouts
To reduce common cause variation is to change the
systemor redesigning the process
Adapted from: The Lean Six Sigma Pocket Toolbox: by Michael L. Georgeet al., McGraw-Hill 2005
Department of Industrial and Management Engineering
AASTMT
IM 746 Lean Six Sigma
Examples: Common Causes
Inappropriate procedures
Poor design
Poor maintenance of machines Poor maintenance of machines
Poor working conditions, e.g. lighting, noise, dirt,
temperature, ventilation
Substandard raw materials
Quality control error
Vibration in industrial processes
6 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean Six Sigma- Lecture Handouts
Ambient temperature and humidity
Normal wear and tear
Variability in settings
Computer response time
http://en.wikipedia.org/wiki/Common-cause_and_special-cause (Accessed: 18.12.2010)
IM 746 Lean Six Sigma
4 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean 6 Sigma - Lecture Handouts
Department of Industrial and Management Engineering
AASTMT
IM 746 Lean Six Sigma
Special Causes of Variations
Special cause : variation above and beyond common
cause variation, arising from factors that are not
always present in the process always present in the process
Every process has common cause variation with
special cause variation is said to be out of control
Variation from special causes is not random (identifiable
patterns) but its impact is unstable and unpredictable.
Reduce special cause variation by tracking down and
eliminatingthe specific assignable root
7 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean Six Sigma- Lecture Handouts
eliminating the specific, assignable root
cause(s), looking for "what's different" in the process
when the special cause variation appears
Adapted from: The Lean Six Sigma Pocket Toolbox: by Michael L. Georgeet al., McGraw-Hill 2005
Department of Industrial and Management Engineering
AASTMT
IM 746 Lean Six Sigma
Examples: Special Causes
Poor adjustment of equipment
Operator falls asleep
Faulty controllers
A special-cause failure is a failure
that can be corrected by changing a
Faulty controllers
Machine malfunction
Computer crashes
Poor batch of raw material
Power surges
Abnormal traffic (click-fraud) on web ads
component or process.
A common-cause failure is
equivalent to noise in the system
and specific actions cannot be
made to prevent for the failure
8 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean Six Sigma- Lecture Handouts
Abnormal traffic (click fraud) on web ads
Extremely long lab testing turnover time due to
switching to a new computer system
Operator absent
http://en.wikipedia.org/wiki/Common-cause_and_special-cause (Accessed: 18.12.2010)
IM 746 Lean Six Sigma
5 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean 6 Sigma - Lecture Handouts
Department of Industrial and Management Engineering
AASTMT
IM 746 Lean Six Sigma
Time series plots (Run charts)
Collect data and be sure to track the order in which the
data were generated by the process.
Mark off the data units on the vertical (y) axis and mark Mark off the data units on the vertical (y) axis and mark
the sequence (1, 2, 3) or time unit (11 Mar, 12 Mar,
13 Mar) on the horizontal (X) axis.
Plot the data points on the chart and draw a line
connecting them in sequence
Determine the median and draw a line at that value on
the chart
9 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean Six Sigma- Lecture Handouts
the chart
Count the number of points not on the median.
Circle then count the number of runs
A "run" is defined as series of consecutive points that
do not cross the median
Adapted from: The Lean Six Sigma Pocket Toolbox: by Michael L. Georgeet al., McGraw-Hill 2005
Department of Industrial and Management Engineering
AASTMT
IM 746 Lean Six Sigma
Example:
The median is the midpoint of a ranked order set
of data. To determine the median, arrange the
data in ascending or descending order. The
median is the value at the center (if there is an
odd number of data points), or the average of the
two middle values (if there is an even number of
data points). The symbol for the median is X with
a tilde (~) over it
MEDIAN
( )
10 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean Six Sigma- Lecture Handouts
Adapted from: The Lean Six Sigma Pocket Toolbox: by Michael L. Georgeet al., McGraw-Hill 2005
IM 746 Lean Six Sigma
6 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean 6 Sigma - Lecture Handouts
Department of Industrial and Management Engineering
AASTMT
IM 746 Lean Six Sigma
Example
MEDIAN
11 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean Six Sigma- Lecture Handouts
Points on the median are not counted toward total points
Points on the median do not interrupt the run if the median is not crossed
(points 11 to 15 )
Adapted from: The Lean Six Sigma Pocket Toolbox: by Michael L. Georgeet al., McGraw-Hill 2005
Department of Industrial and Management Engineering
AASTMT
IM 746 Lean Six Sigma
How to analyze a run chart ?
Use the Run Chart Table (next page) to interpret the
results.
The table gives you a range of runs you can expect to The table gives you a range of runs you can expect to
see if the data are random (common cause variation
only) and from a normal distribution.
If the number of counted runs is bigger or smaller
than expected, you may have special cause
i i i h h d l
12 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean Six Sigma- Lecture Handouts
variation in the process or the data are not normal.
Adapted from: The Lean Six Sigma Pocket Toolbox: by Michael L. Georgeet al., McGraw-Hill 2005
IM 746 Lean Six Sigma
7 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean 6 Sigma - Lecture Handouts
Department of Industrial and Management Engineering
AASTMT
IM 746 Lean Six Sigma
Run chart table
# pts
not on
median
Lower
limit of
runs
Upper
limit of
runs
10 3 8
# pts
not on
median
Lower
limit of
runs
Upper
limit of
runs
26 9 18
pts not
on
median
Lower
limit of
runs
Upper
limit of
runs
42 16 27
Recall the example # of pts not on median = 16 , # of runs = 9
No Special causes !
10 3 8
11 3 9
12 3 10
13 4 10
14 4 11
15 4 12
16 6 12
17 5 13
18 6 13
26 9 18
27 9 19
28 10 19
29 10 20
30 11 20
31 11 21
32 11 22
33 11 22
34 12 23
42 16 27
43 17 27
44 17 28
45 17 29
46 17 30
47 18 30
48 18 31
49 19 31
50 19 32
13 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean Six Sigma- Lecture Handouts
19 6 14
20 6 14
21 7 15
22 7 16
23 8 16
24 8 17
25 9 17
35 19 23
36 13 23
37 13 25
38 14 25
39 14 26
40 15 26
41 16 26
60 24 37
70 28 43
80 33 48
90 37 54
100 42 59
110 46 65
120 48 70
Adapted from: The Lean Six Sigma Pocket Toolbox: by Michael L. Georgeet al., McGraw-Hill 2005
Department of Industrial and Management Engineering
AASTMT
IM 746 Lean Six Sigma
Example 2: Trend Case
14 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean Six Sigma- Lecture Handouts
Reference: http://www.balancedscorecard.org/Portals/0/PDF/runchart.pdf (Accessed 03.12.2010)
IM 746 Lean Six Sigma
8 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean 6 Sigma - Lecture Handouts
Department of Industrial and Management Engineering
AASTMT
IM 746 Lean Six Sigma
Example 3: Run Case
15 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean Six Sigma- Lecture Handouts
Reference: http://www.balancedscorecard.org/Portals/0/PDF/runchart.pdf (Accessed 03.12.2010)
Department of Industrial and Management Engineering
AASTMT
IM 746 Lean Six Sigma
Example 4: Cycle Case
16 Copyright Prof. Dr. Aziz Ezzat ElSayed Lean Six Sigma- Lecture Handouts
Reference: http://www.balancedscorecard.org/Portals/0/PDF/runchart.pdf (Accessed 03.12.2010)