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Six-Sigma Quality

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SIX-SIGMA QUALITY The second pillar of the Toyota Production System is Jidoka A system for detecting defects and abnormal conditions in production Automatically ... – PowerPoint PPT presentation

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Title: Six-Sigma Quality


1
(No Transcript)
2
Six-Sigma Quality
  • The second pillar of the Toyota Production
    System is Jidoka
  • A system for detecting defects and abnormal
    conditions in production
  • Automatically stopping a line so that quality
    issues can be quickly addressed.

3
House of Toyota
4
Data Driven Approach
  • In even the leanest manufacturing plants, some
    quality issues arise that are difficult to
    identify and correct
  • Six Sigma is especially effective at identifying
    the root cause of quality problems and
    eliminating defects by reducing variation in
    manufacturing processes

5
Variation - The Root Of All Process Evil
  • As a customer, the worst experience I can imagine
    is being a casualty of process variation. 'It
    doesn't seem that bad,' you may be thinking to
    yourself. Just remember back to the last time
    you

6
Remember When You
  • Went grocery shopping only to select the slowest
    teller in the store
  • Received a haircut that was shorter or longer
    than usual, and definitely not what you asked for
  • Decided to go shoe shopping, but got stuck with
    the most ignorant salesperson available

7
  • Consider the general concept of variation by
    examining the preparation time (in minutes) of 10
    pizzas being prepared by your two local pie
    shops. The times are listed below
  • ABC Pizzeria
  • XYZ Pizza To Go

6.5 6.6 6.7 6.8 7.1 7.3 7.4 7.7 7.7 7.7
4.2 5.4 5.8 6.2 6.7 7.7 7.7 8.5 9.3 10
8
  • If we use common statistical tools, such as Mean,
    Mode and Midrange, we get the following results

ABC Pizzeria XYZ Pizza To Go
Mean 7.15 7.15
Mode 7.7 7.7
Midrange 7.1 7.1
9
  • From these results the two pizza parlors have the
    same measures of central tendency, so, on
    average, customers wait the same amount of time
    for pizzas at the two restaurants
  • Based on these measurements alone, we cannot see
    any distinguishable difference between the two
    processes

10
  • Return to the original data points, There is a
    very distinguishable difference ABC Pizza has
    preparation times with much less variation than
    the times for XYZ Pizza.
  • ABC Pizzeria
  • XYZ Pizza To Go

6.5 6.6 6.7 6.8 7.1 7.3 7.4 7.7 7.7 7.7
4.2 5.4 5.8 6.2 6.7 7.7 7.7 8.5 9.3 10
11
  • If all other characteristics of the pizza (taste,
    temperature, size, topping quality, service
    friendliness, etc.) are equal, customers are
    likely to prefer the ABC Pizza where they will
    not become annoyed by being the one person whose
    pizza preparation time is much slower than the
    others

12
  • Six Sigma at many organizations simply means a
    measure of quality that strives for near
    perfection
  • Six Sigma is a disciplined, data-driven approach
    and methodology for eliminating defects
  • Driving towards six standard deviations between
    the mean and the nearest specification limit in
    any process -- from manufacturing to
    transactional and from product to service

13
  • From a manufacturing standpoint, that means just
    3.4 defects per million products or parts made
  • Surprisingly, manufacturing 99 without defects
    means youll have 10,000 defects per million
    and at 95 that number jumps to 50,000 defects.

14
  • The quality tools and techniques that were named
    Six Sigma in 1986 by Motorola (actually by a
    Motorola engineer named Bill Smith) are not new
  • They were developed over the past 50 or more
    years, through the work of quality experts such
    as Deming, Juran and others.

15
The Journey
16
Data Driven Approach
  • Despite the use of the term today, Six Sigma is
    actually a numerical measurement of quality
  • To achieve Six Sigma, precisely 99.99966 of what
    you do must be without defects

17
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18
Key Concepts of Six Sigma
  • Critical to Quality
  • Defect
  • Process Capability
  • Attributes most important to the customer
  • Failing to deliver what the customer wants
  • What your process can deliver

19
Key Concepts of Six Sigma
  • What the customer sees and feels
  • Ensuring consistent, predictable processes to
    improve what the customer sees and feels
  • Designing to meet customer needs and process
    capability
  • Variation
  • Stable Operations
  • Design for Six Sigma

20
Deming Juran
It is not necessary to change. Survival is not
mandatory.
W. Edwards Deming
"Without a standard there is no logical basis for
making a decision or taking action." Joseph M.
Juran
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