Professional Documents
Culture Documents
Six-Sigma Quality
9-3
OBJECTIVES
Quality Specifications
Costs of Quality
Appraisal Costs
Internal Failure
Costs
9-7
Number
of defects
DPMO = x1,000,000
Number of
opportunit
ies xNo.of units
forerrorper
unit
9-9
Example
Example of of Defects
DefectsPer
Per Million
Million So,
So,for
forevery
everyone
one
Opportunities million
millionletters
Opportunities(DPMO)
(DPMO) calculation.
calculation. delivered
letters
Suppose deliveredthis
this
Suppose we weobserve
observe 200
200 letters
letters city’s
city’spostal
postal
delivered
delivered incorrectly
incorrectly to
tothe
the wrong
wrong managers
managerscan can
addresses
addresses in inaa small
small city
city during
duringaa expect
expecttotohave
have
single
single day
day when
whenaa total
total of
of 200,000
200,000 1,000
1,000letters
letters
letters incorrectly
incorrectlysent
sentto
letterswere
were delivered.
delivered. What
What isisthe
the the
to
DPMO thewrong
wrongaddress.
address.
DPMO in in this
thissituation?
situation?
200
DPMO = = 1, 000
x1,000,000
[ 1] x200,000
Cost
Cost of
of Quality:
Quality:What
Whatmight
mightthat
that DPMO
DPMO mean
mean in
in terms
terms
of
of over-time
over-timeemployment
employment to
tocorrect
correct the
theerrors?
errors?
9-10
Step 1 - Define
2 - Measure
2 – Measure (continued)
2 – Measure (continued)
Process
Lower Tolerance Mean = 15.875 Upper Tolerance
= 15.2 Std. Dev. = .529 = 16.8
What percentage of boxes are defective (i.e. less than 15.2 oz)?
– Decrease Variation
– Center Process
– Increase Specifications
9-19
12σ
6σ
3 2 1 0 1 2 3
9-20
12σ
3 2 1 0 1 2 3
9-21
Step 5 – Control
Material
No,
Received Continue…
Inspect
from
Material for Defects
Supplier
Defects found?
Yes
Can
Canbebeused
usedto
to
find
findquality
quality Return to
problems
problems Supplier
for Credit
9-23
Analytical Tools for Six Sigma and Continuous Improvement: Run Chart
Can
Canbebeused
usedtotoidentify
identify
when
whenequipment
equipmentor or
processes
processesarearenot
not
behaving
behavingaccording
accordingtoto
Diameter
specifications
specifications
0.58
0.56
0.54
0.52
0.5
0.48
0.46
0.44
1 2 3 4 5 6 7 8 9 10 11 12
Time (Hours)
9-24
Can 80%
Can be be used
used
to
to find
find when
when
80%
80% of of the
the Frequency
problems
problems
may
may be be
attributed
attributed to to
20%
20% of of the
the
causes
causes
Design Assy. Purch. Training
Instruct.
9-25
Can
Canbebeused
usedtotokeep
keeptrack
trackof
of
defects
defectsororused
usedtotomake
makesure
sure
people
peoplecollect
collectdata
datain
inaa
Monday correct
correctmanner
manner
Billing Errors
Wrong Account
Wrong Amount
A/R Errors
Wrong Account
Wrong Amount
9-26
Can
Canbebeused
usedto
toidentify
identifythe
thefrequency
frequencyof ofquality
quality
Number of Lots
defect
defectoccurrence
occurrenceand
anddisplay
displayquality
quality
performance
performance
0 1 2 3 4 Defects
Data Ranges in lot
9-27
Possible The
Theresults
Possiblecauses:
causes: results
or
or effect
effect
Machine Man
Environment Effect
Method Material
Can
Canbebeused
usedto
tosystematically
systematicallytrack
trackbackwards
backwardsto
to
find
findaapossible
possiblecause
causeof
ofaaquality
qualityproblem
problem(or
(or
effect)
effect)
9-28
Can
Canbebeused
usedto
tomonitor
monitorongoing
ongoingproduction
productionprocess
process
quality
qualityand
andquality
qualityconformance
conformanceto
tostated
statedstandards
standardsof
of
quality
quality
1020
UCL
1010
1000
990
980
LCL
970
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
9-29
• Shingo’s argument:
– SQC methods do not prevent defects
– Defects arise when people make errors
– Defects can be prevented by providing
workers with feedback on errors
• Poka-Yoke includes:
– Checklists
– Special tooling that prevents workers from
making errors
9-32
4. Analyze data
9-35
Question Bowl
Question Bowl
Question Bowl
Question Bowl
Question Bowl
Question Bowl
Question Bowl
End of Chapter 9