BY Dr.R.

Raju Professor Dept of Indl Engg Anna University

INTRODUCTION
Quality is an important aspect of any manufacturing process. Only high quality products can survive in the market. Before 1980s most of the industries produced the

products and the defects were detected and

segregated (inspection).

CONTD..
Detection concept ensured the quality but increased the rework and rejections.

In the present scenario, it is necessary to achieve the

global quality which demands prevention concept. Six sigma is one of the most important prevention concepts.

CONTD
Six sigma is a powerful approach to achieve break through improvements in manufacturing ,engineering and

business process.

This approach relies on advanced statistical methods that compliment the process and product knowledge to reduce variation in processes.

CONTD..

It is a new way of doing business that would eliminate

the existing defects efficiently and would prevent

defects from occurring

MEANING OF QUALITY
Under six sigma quality is defined as a state in which value entitlement is realized for the

customer and provider in every aspect of the

business relationships.

What is Six Sigma

Metric (Statistical Measure ) Used for representing Process Variation Higher the number before (3,4,5) lesser the variation, higher the product quality and customer satisfaction.

Value Symbol Method Benchmark Tool

Metric
Philosophy

Vision

DEFINITION OF SIX SIGMA

SIX SIGMA IS DEFINED AS a disciplined ,data driven approach of continuously improving process quality and productivity to result in bottom line profitability.

ORIGIN OF SIX SIGMA

In 1980,motorola faced overseas competition seeking to dominate the electric industry by producing consistently higher quality products.

Based on this significant threat to its leadership position, Motorola chairman Bob Galvin announced an initiative ,which is dedicated to improve the quality of internal process by a factor of 10 within 2 years.

ORIGIN OF SIX SIGMA CONTD..

The internal focus of the program emphasized the idea to improve results for their customers.

Six sigma was born.

There after companies like General Electric and Allied Signals

implemented six sigma successfully.

SIX SIGMA approach

BUSINESS PROBLEM BUSINESS SOLUTION

DATA DRIVEN ANALYTICAL

STATISTICAL PROBLEM STATISTICAL SOLUTION

SIX SIGMA CONCEPT

If the process variation is controlled to 6 levels ,the defects expected is 3.4 parts per million opportunities,even if there is a shift in the process mean by 1.5.

Understanding Variation

Variation / Standard deviation

Mean or Average

Center / Location

Spread / Dispersion

Understanding Variation

1 2 3

68.27% 95.45% 99.73%

2 3

Normal or Symmetric Distribution

Where : Standard Deviation Target

6
Total Process Variation = 6

6
3

Natural or inherent variation experienced in a process. Valid only when the process is in a state of statistical control

Comparison
LSL USL

VARIATION
ACTUAL PERFORMANCE VS SPECIFICATIONS Or Customer Requirements

Actual vs Specified Comparison

Total Process Variation = Tolerance or

6
Tolerance(T) LSL USL

6 = T

2700 ppm

Actual vs Specified Comparison

Total Process Variation < Tolerance

6 < T or T=8

6
LSL Tolerance(T) USL

64 ppm

Actual vs Specified Comparison

Total Process Variation < Tolerance

6 < T T=10

or

6
Tolerance(T)

LSL

USL

0.6 ppm

Actual vs Specified Comparison

Total Process Variation < Tolerance

3 3

6 < T

or

T=12

6
Tolerance(T) LSL USL

0.002 ppm or 2 ppb

Actual vs Specified Comparison

1.5

Total Process Variation < Tolerance 6 < T or T=12

(with 1.5 shift)

4.5

1.5

6
LSL
Tolerance(T)

USL

3.4 ppm

CRITICAL SUCCESS FACTORS FOR SIXSIGMA

Customer centricity

Voice of the customer. Requirements. Critical to quality (CTQ) Defects. Design for six sigma.

Financial results. Management engagement Resource commitment. Execution infrastructure. Team work

KEY MESSAGES OF SIXSIGMA

Everything starts with the customer. The infrastructure for cultural change is the most powerful contribution of six sigma. Decision about which projects to pursue must be based at least in part on the potential impact on NPV. Sustained improvement is possible only with management engagement. CEO goals are translated to frontline projects and coordinated through an organization of people and technical resources. A standard problem-solving process and associated tool set provides the means for basing decisions on data.

THANK YOU