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A. CHAPTER OBJECTIVES
B. DEPLOYING THE
BREAKTHROUGH STRATEGY
C. SIX SIGMA DEPLOYMENT
ROADMAP
2-1
CHAPTER OBJECTIVES
2-2
100,000
10,000
1,000
Average
Company
100
10
World-Class
1
2
DEFINE PHASE
OBJECTIVES
Identify product/process to be improved, project
authorization, select team, establish initial baseline
measurements and improvement goals.
Output Includes:
Project description, improvement goals,
authorization to start.
Initial process/product baseline measurements.
Team Selection.
2-4
2-5
Inputs:
Raw
Materials,
components,
etc.
Establish the
Controllable Inputs
performance
X1 X2 X3
baseline
Quality
Characteristics:
Outputs LSL
USL
Y1, Y2, etc.
The Process
Z1 Z2 Z3
Uncontrollable Inputs
2-6
2-7
2-8
Inputs:
Raw Materials,
components,
etc.
USL
Z1 Z2 Z3
Uncontrollable Inputs
2-9
2-10
IMPROVE PHASE
OBJECTIVES
Team switches from thinking broadly to a focused mindset.
You know what the cause is, what changes can be made and
what methods will achieve the desired effects.
Confirm key process input variables (Xs).
Quantify the effect of Xs on output variables (Ys).
Identify optimum operating range of Xs.
Modify process to stay within acceptable range.
Test your solution to assure you have reduced/eliminated
causes of variation.
2-11
X2 X3
X
Inputs:
Raw Materials,
Components,
Etc.
Quality
Characteristics:
Outputs
LSL
USL
X
LSL
Z1
USL
Z2 Z3
Uncontrollable Inputs
2-12
2-14
Inputs:
Raw Materials,
Components,
Etc.
Controllable Inputs
X1 X2 X3
Quality
Characteristics:
Outputs
LSL
Y1, Y2, etc.
USL
The Process
Z1 Z2 Z3
Uncontrollable Inputs
2-15
2-16
Sweet Fruit
Design for
Manufacturability
Process
ProcessEntitlement
Entitlement
Bulk of Fruit
Process Characterization
and Optimization
---------------------------------Low Hanging Fruit
Seven Basic Tools
---------------------------------Ground Fruit
Logic and Intuition
We don't know what we don't know
We can't act on what we don't know
We won't know until we search
We won't search for what we don't question
We don't question what we don't measure
Hence, We just don't know
Ground Fruit - problems which can be solved using logic and intuition.
Low Hanging Fruit - these are problems where the solutions are obvious and in
most cases, can be solved utilizing basic problem solving tools.
Bulk of Fruit - problems where the cause and solutions are not obvious and
require full deployment of the Six Sigma Breakthrough Strategy.
Sweet Fruit - in order to leap from 4 and 5 sigma to 6 sigma, principles of
Design for Six Sigma (DFSS) will be necessary.
2-17
DEFINE
Step
Description
Tools
Deliverables
1.
Project
authorization
2.
Project tracking
software
3.
Problem Statement
Baseline metrics and
goals
Team
Metric graph with goal
line
2-18
MEASURE
4.
5.
6.
7.
Description
Tools
Capability.
Re-evaluate/update project
description, baseline metrics,
goals benefits and costs.
Process Mapping
Process Modeling
Value Stream Mapping
Data Collection
Cause & Effect
Matrix
FMEA
Gage R & R
Process Capability Study
Cp, Cpk
SPC Charts
Sigma (Z)
Ishikawa
Diagrams
Brainstorming
Deliverable
Process Map
Value Stream Map
FMEA
Control Plans
(Process controls)
Cause & Effect Matrix
Initial Ranking of
KPIVs
Pareto Charts
Measurement System
Analysis
Process Capability Study
2-19
ANALYZE
Step
Description
8.
9.
10.
11.
Re-evaluate/update project
description, baseline metrics,
goals, benefits and costs.
Tools
Process Simulation
SPC Charts
Ishikawa Diagrams
Hypothesis testing
Graphical Analysis
Time Trap Analysis
Deliverable
2-20
IMPROVE
Step
Description
12.
13.
14.
15.
Tools
Correlation &
Regression Analysis
Multi-Vari Analysis
DOE:
Full Factorial
2K Factorial
Fractional Factorial
Process Optimization
Lean Tools
Deliverable
Prioritized list of
KPIVs needing
further study.
Document KPIVs
operating limits
DOE Reports
List of solutions
impacting KPIVs
Improvement plans
Documented
improvement plan
and actions.
2-21
CONTROL
Step
Description
16.
17.
18.
19.
Document project.
20
Tools
Deliverable
Documented Process
Control plans
List of system
improvements
Capability studies
Final project
presentation
Final report
2-22