Six Sigma - PowerPoint PPT Presentation

Loading...

PPT – Six Sigma PowerPoint presentation | free to download - id: 3b4f43-NjgxO



Loading


The Adobe Flash plugin is needed to view this content

Get the plugin now

View by Category
About This Presentation
Title:

Six Sigma

Description:

Six Sigma What is it? Robert Fruit SSBB CQE Page I 2 Guaranteed Success Page I 2 Define the Problem Commercial Airline Take Off Pilot walks around the plane ... – PowerPoint PPT presentation

Number of Views:48
Avg rating:3.0/5.0
Slides: 71
Provided by: apcuOrgpr
Learn more at: http://www.apcu.org
Category:
Tags: sigma | six

less

Write a Comment
User Comments (0)
Transcript and Presenter's Notes

Title: Six Sigma


1
  • Six Sigma
  • What is it?

Robert Fruit SSBB CQE
2
Page I 2 Guaranteed Success
3
Page I 2 Define the Problem
4
Commercial Airline Take Off
  • Pilot walks around the plane
  • Alaska Air plane crashes because of failed
    cable to vertical stabilizer
  • Pilot checks controls from cockpit
  • United Air Lines plane runs out of fuel when
    captain asked for gallons of gas and was given
    litters of gas
  • Pilot goes through lengthy check list
  • All procedures have historical reasons
  • Have some procedures outlived their usefulness
  • This procedure has 6 s level of success, it is
    not Six Sigma

5
Six Sigma is a Process for Improvement
  • Six Sigma is different than the procedures that
    preceded it
  • Emphasizes that you must have top management
    involvement from the start
  • Always has a limited time frame
  • Has a written goal
  • Has determined a means to measure success

6
DMAIC
  • Define
  • Measure
  • Analyze
  • Improve
  • Control

7
Six Sigma is about Measuring
  • Six Sigma is all about measuring to prove results
    and improved profit. It is also about shaking
    things up. An organization not willing to change
    is not prepared to start a Six Sigma project

8
Make no Arbitrary Decisions
  • Six Sigma is based on measured values
  • Many of those measurements are statistical
  • there are many degrees of probability, some
    nearer the truth than others
  • Christian Huygen 17 century from
  • Absolute Zero, Shachtman, 1979

9
Not every problem is a Six Sigma issue
  • Daily issues are no Six Sigma issues
  • Opened ended problems are not Six Sigma issues

10
Six Sigma issues have defined periods
  • Part of defining a Six Sigma issues is setting a
    time limit for the Six Sigma effort.
  • Typical time period is 3 months
  • Some have less time
  • Rarely does a Six Sigma effort have more than 9
    months

11
Where to Start
  • Look for KIPV (Key Input Variables)
  • That effect KOPV (Key Output Variables)
  • KIPV
  • Things that influence KOPV
  • KOPV
  • Things that are important to your customers

12
Voice of the Customer
  • KOPV is the voice of the customer
  • If it is important to the customer it is a KOPV
  • Appearance
  • On time delivery
  • Meet its requirements
  • support

13
Who is the customer
  • The person outside your company who buys your
    product
  • The person inside your company who uses your
    product next
  • Both

14
The Purpose of Business
  • Take a product
  • Perform your procedures on it
  • Increase the value of the product
  • Have a customer (internal or external) who is
    willing to buy that increase value

15
Where did Six Sigma Begin
  • Motorola made Quasar TVs in Chicago
  • Lost money on every set that left the plant
  • Problems with quality of sets
  • Problems with worker motivation
  • Sold Manufacturing plant to a Japanese firm
  • Got workers involved in manufacturing process
  • Reduce defect to 1/20 of former level
  • Same plant, same workers
  • Made big profits
  • Motorola was embarrassed
  • CEO swore never to let this happen again
  • Started people on the path that became Six Sigma

16
GE gets into Six Sigma
  • Under Jake Walsh GE starts to use Six Sigma
    methods
  • One of the biggest money savers was in reports.
  • People went around and talked to managers about
    the mountain of reports they got every month
  • Found that only a few of the reports were
    actually used
  • Eliminated unused reports
  • Estimated savings about 1 billion per year

17
TQM
  • Who remembers TQM
  • It tended to be a top down system
  • Upper management demanded better quality from the
    people who worked for them
  • Who remembers Quality is our business
  • TQM tended to be short term attention
  • As soon as quality problem solved move onto next
    project
  • Lack of follow up

18
Six Sigma is Long Term
  • Get top management involved from the beginning
  • Clearly define the problem
  • Measure performance
  • Measure results of improvements
  • Report on saved by improvements
  • Set up system to monitor results after project is
    concluded

19
The Cost of Poor Quality
  • Many companies operate at 3-4 s levels
  • 25-40 of revenue used for fixing defects
  • Rework parts
  • Sorting out defective parts
  • Scrape
  • Extra employees
  • Most of these companies dont realize what poor
    quality is costing them
  • Companies working at 6 s level typically spend 5

20
Probability and Central Tendancy
  • Typical show single probability curve
  • The central tendency can shift from the ideal
    position
  • This increases the area in the tail regions which
    is a measure of defects

21
Six Sigma Defects per Million
  • Allow the central tendency move by 1.5 standard
    deviations either side of theoretical perfection
  • Page II-3

22
Defects per Million Opportunities
  • DPP Defects per part
  • DPP defects / parts
  • O Number of opportunities for a defect per part
  • DPMO DPP / O 1,000,000

23
Six Sigma 3.4 DPMO
  • Achieving Six Sigma level is having 3.4 DPMO
  • Measure defects at start of process
  • Convert to s level
  • Measure defects after improvement
  • Convert to s level

24
Six Sigma is more than DPMO
  • DPMO in manufacturing
  • DFSS Design for Six Sigma
  • New process designed to meet Six Sigma from the
    beginning
  • Lean Manufacturing
  • In general almost anything that significantly
    improves profits

25
Punch Press Problem
  • Bid on project based on 100 parts per minute
  • Best they can achieve is 80 parts per minute
  • They were going to loose a lot of money on the 3
    year contract

26
Hand placed
  • The pieces over lap each other
  • Must be precisely placed for machine pickup at
    customer
  • NO DEFECTS allowed in trays

27
80 Pieces Per Minute
  • Punch press no defective parts
  • Operators must untangle parts on round table
  • Operators barely keep up with flow of parts
  • Unstack tray for parts

28
Process Flowchart
29
Things Under Consideration
  • Process Issues
  • Improving manual packing methods
  • Un-stacking of delivered trays
  • Running machine at 180 SPM
  • maintain current quality
  • Using 2 inch or 3 inch stroke press
  • Staging and storage of trays
  • Analyzing cost of materials

30
Change Packing
  • Receive 1,000 trays to a box
  • Hard to unpack from shipping box
  • Trays cling together
  • Must be separated without distorting box
  • Come from Phoenix
  • Send 16 trays out in special boxes
  • Arrange for local manufacture of trays
  • Receive in the same boxes used to ship product

31
Change Personnel Layout
  • Tests showed that packers on linear conveyor
    packed faster
  • Parts did not stack on each other

Improved personnel layout
Original personnel layout
2
2
3
3
1
4
4
1
32
Original Costs
33
Improved Costs
34
Improved Profits
35
Some Keywords
  • DMAIC
  • Voice of the Customer
  • KIPV
  • KOPV
  • DPMO

36
High Definition Television
37
HD TV on a computer
  • ATI makes a HD tuner for PCI slot HDTV Wonder
  • Works only with broadcast HD signal
  • Minimum standards do not come close to describing
    computer requirements
  • Do not get without having AGP 8x or PCI express
    slot
  • Designed to be part of multi-media computer
  • Has remote control, USB plug in receiver

38
Extreme Tech Comment
The card itself features a Philips HDTV tuner box
but ATIs NXT2004 receiver chip does much of the
heavy lifting. The NXT2004 VSB (vestigial
sideband modulation)/QAM (quadrature amplitude
modulation) Receiver is designed for off-air and
cable digital television receivers, set-top
boxes, PCDTV, and datacast applications where
cost, low power and industry-leading performance
are a must. The NXT2004 Multimode VSB/QAM
demodulator can work in either the ATSC
compliant 8 VSB mode for terrestrial
broadcasting, or DICSIS-compliant 64 QAM or 256
QAM modes for Digital TV-Cable Connect and
Digital TV Cable Interactive reception. However,
in the HDTV Wonder product, the NXT2004 is set up
only as a 70-channel off-the-air HDTV receiver
39
ATI HDTV Card
40
HDTV is not CPU hog
  • 2.8 G-Hz celeron
  • 768 Meg Ram
  • 7200 RPM HD
  • No AGP
  • No PCI express
  • 720P black image
  • 1080i black image
  • Demand Direct X 9
  • Plus more

41
ATI RADEON 9250 PCI
42
Things I have Learned
  • If you go for HDTV Wonder you are still in the
    pioneer era (arrows in the back)
  • The card assumes you are creating a media
    computer (rich set of software features)
  • Remote control plus USB RF receiver
  • Needs tweaking to start HD TV
  • S video and component Video, left, right input
  • Not every feature works as well as you would like
  • TV directory
  • Create DVD disk
  • Keep it all ATI (HDTV and video card)
  • Complaints about GE-Force video cards

43
And now to Robts
  • There are children ready robot projects
  • No not the False Maria
  • Based on BASIC Stamp module

44
2 Robots
45
BASIC Stamp
Serial SignalConditioningConditions
voltagesignals between PC serialconnection (/-
12V) and BASIC Stamp (5V) for Programming.
5V RegulatorRegulates voltageto 5V with a
supply of 5.5VDC to 15VDC
EEPROMStores the tokenized PBASIC program.
ResonatorSets the speed at whichinstructions
are processed.
Interpreter ChipReads the BASIC program from the
EEPROM and executes the instructions.
46
BASIC Stamp
Pin 1 SOUT Transmits serial data during
programming and using theDEBUG instruction
Pin 24 VIN Un-regulated input
voltage (5.5-15V)
Pin 23 VSS Ground (0V)
Pin 2 SIN Receives serial data during
programming
Pin 3 ATN Uses the serial DTR line togain the
Stamps attention for programming.
Pin 21 VDD Regulated 5V.
P0
P15
P1
P14
Pin 4 VSS CommunicationsGround (0V).
P2
P13
P3
P12
P4
P11
P5
P10
P6
P9
P7
P8
47
BOE BOT Box
48
Board of Education Robot BOE Bot
49
BOE BOT Circuit Board
50
BOT motherboard
  • The Board of Education makes it easy to connect
    devices, power up and program.

5V regulator
Battery
Servo Connections
Wall DCSupply
Power Header
Power OnLight
I/O Header
Breadboard
Serial ProgrammingPort
Reset Switch
Off/Module Power/Servo Power
Off/Module Power/Servo Power
51
Programming
  • A program is writtenin the BASIC Stamp Editor.

52
Instructions
53
Instruction
  • The FREQOUT command sends high/low signals to the
    specified pin at the frequency and for the
    duration defined.FREQOUT Pin, Duration, Freq1,
    Freq2
  • To play a note at 2000Hz which lasts 1.5 seconds

54
Instructions
Inner Loop
Outer Loop
The inner loop is performed fully
everyrepetition of the outer loop.
55
Instructions
When index 0
56
Instructions
When index 1
57
Instructions
Each CASEwill be checked
58
Shows how resources are used
  • View memory
  • View registers

59
BOE BOT Program
  • 'Robotics with the Boe-Bot - BoeBotForwardTenSecon
    ds.BS2
  • 'Make the Boe Bot roll forward for 10 seconds
  • 'STAMP BS2
  • 'PBASIC 2.5
  • counter VAR Word
  • FREQOUT 4, 2000, 3000 'create sound
  • FOR counter 1 TO 407 'forward 10
    seconds
  • PULSOUT 13,850 'left wheel
    forward
  • PULSOUT 12,650 'right wheel
    forward
  • PAUSE 20
  • NEXT
  • END

60
SUMO BOT Box
61
SUMO BOT
62
Sumo Bot
63
SUMO BOT Circuit Board
64
SUMO Bot 2 CPU
  • Motion uses PIC16C505 processor for wheels
  • Simplifies motion commands

65
SUMO BOT Programming
  • Simpler commands because of built in functions
  • Must include predefined constants

PAUSE 100 RobotData RobotForward GOSUB RobotSend
66
SUMO BOT Remote Control
67
Remote Control Details
68
Pretend it is like Sojourner
69
Where to go from here
70
Which Bot do you want
  • BOE BOT
  • More hardware assembly
  • Must adjust software to hardware performance
  • Comes with lots of extra parts
  • More learning opportunities
  • SUMO BOT
  • Quick assembly
  • Starts running immediately
  • 4 built in behaviors
  • Remote control
  • Kids like simpler requirements better
About PowerShow.com