六西格瑪基礎知識簡介

1、QIAImproveQualityReduceCostProductivityImprovesCaptureMarketProvidesjobs andmore jobsModelsofthe relationshipsaffecting qualityandbusinessperformanceDemingsModel:less rework,less scrapIncreasecycletime,increasethroughputbetterquality,lowerpriceOverallsocietybenefitsCOST OF POORQUALITY(COPQ)ExternalF

2、ailure CostsWarrantyAdjustmentsRepairsCustomerServiceReturnedGoodsReturnedRepairedGoodsProduct RecallsProduct LiabilitySuitsOpportunityCostsInternalFailure CostsScrapReworkRE-INSPECTION of ReworkDowngradingBecause of DefectsLossesCaused by VendorScrapDowntimeCausedbyDefectsFailure Analysis.Appraisal

3、CostsReceivingInspectionIn-process InspectionLaboratory InspectionOutside LaboratoryEndorsementsSetupforTestingMaintenanceofTest EquipmentQuality AuditsCalibrationofQuality Equipment.Prevention CostsQuality EngineeringDesignand Development of QualityEquipmentDesignVerification andReviewtoEvaluatethe

4、 QualityofNew ProductsQuality TrainingQuality Improvement ProjectsQuality DataGathering Analysis andReportingOtherProcess ControlActivitiesUsed to PreventDefectsLost OpportunityScrapReworkInspectionWarrantyRejectsLost salesLate deliveryEngineeringchangeordersLong cycle timesExpediting costsExcessinv

5、entoryTheCostofPoor Quality(COPQ) “Iceberg”TraditionalQuality CostsAdditional Costs of PoorQuality(intangible)(tangible)4-8%25-35%(Easily Identified)(Difficult or impossibletomeasure)Lost Customer LoyaltyMore SetupsSixSigmaPhilosophyWeareinbusinesstomakemoneyWemake money by satisfyingneedsWeareablet

6、osatisfy needs by doingEveryneed/do pairisaninteractionTheaim of customer focus is on improvingneed/do interactionRepetition of thesame actionconstitute aprocessImprove ourbusinessmeansimprovementofourprocessesCustomersneedproducts/serviceson-time,with zerodefects,withlowercostAsprocess capabilityim

7、proves, theproduct qualityincreasesAsquality increases,costsand cycle-timegodown.Thereduction of defects, cycle-time, costleadstoimprovedcustomersatisfactionAscustomersatisfactionimproves, thelikelihood of doing business increasesAsbusinessincreases, we (asindividual andsociety)grow andprosperWhat i

8、s SixSigma?Sigmaisa statistical unitofmeasurewhichreflectsprocess capability.Thesigmascaleofmeasureisperfectlycorrelatedtosuch characteristicsasdefects-per-unit,partspermilliondefective(PPM), anda probability of afailure/error.Thesigmavalueindicates howoftendefects arelikelytooccur. Thehigherthe sig

9、ma value,thelesslikelyaprocess willproducedefects.Assigmaincreases,costsgodown,cycletime goesdown,and customer satisfactiongoes up.What is themeaning of quality?99%Good(3.8 Sigma)99.9997%Good (6 Sigma)20,000lostarticlesofmail perhourSevenarticlesofmail lostper hourUnsafedrinkingwaterfor almostOne un

10、safeminuteeverysevenmonths15 minuteseachday5,000incorrectsurgicaloperations1.7incorrectoperationsperweekperweek2 short or longlandingsatmostmajoroneshortorlonglanding every fiveairportseach dayyearsateach airport200,000 wrong drugprescriptionsperyear68wrongdrug prescriptionsper yearNoelectricityfors

11、evenhourseachmonthOnehourwithout electricity every34yearsSixSigmaIs.SixSigmaisdisciplinedmethodologyfor continuousimprovementforReducingprocess variability andkeeping it reducedachieve benefits fromimprovements in:betterproduct/process qualityreducescarpand reworkreducecycletimebetterproduct/process

12、 designreducemajorexpansesA toolset to makethatchangepracticalEmpoweredpeople havethe controltheyneed to improvethe waythey workA commonlanguagefordiscussing,measuring andcomparingprocesscapabilitiesA powerful competitive advantage.-6-5-4-3-2-1 X+1+2+3+4+5+6 NormalDistributionShifted 1.5Process Capa

13、bility(Sigma)PPMYield2308,53769%366,80793.3%46,21099.3%523399.98%63.499.9997%SigmaMeasures- ProcessCapabilityPerformanceLevelSIGMA% Yield# of DefectsperMillion (DPM)A+699.999663.4A599.9767233B499.37906,210C393.366,807D269308,537F131691,462GoodWorld-ClassAverageGoodWorld-ClassAverageCost ofQuality %1

14、%ofsales5 -15% of sales15- 25%ofsales25- 40%ofsalesC93.366,8073EstablishorganizationalmeasurementsIdentifythesigmalevelEstablishCOPQmeasurementprocessIdentifythemajorareasfor improvement3 to 4sigmameans15%to25%costofsales:- Which means if yoursalesis$100millions,you cansave up to $25millionsbyimplem

15、entingSix Sigma program.Thesavingsiscontinuous basis yearoveryearWhat is theBenefitsofSixSigma?OutputMeasurementFailure rate(internal andexternal)WarrantycostRepaircostperunitCycletime perunitCycletime fornewproductdevelopment# of engineering changesSupplierissuesWIPinventory costFinishedgoodsinvent

16、oryDefects productarrivalatcustomer# of serviceeventsLearnhowthe companieslike GeneralElectric, AlliedSignal,Motorola, Lockheed Martin,AmericanExpress,J.P.Morgan&Chase,and othersuseSix Sigma methodologiestoreduce defects, improveprocesses,lowercost,higherprofit,increasecustomersatisfaction, anddrive

17、improvementtoa newlevels.“The SixSigmaQuality initiatives haslowered GEscostsbydramatically reducing rework,simplifyingprocesses,andreducingdirect material costs.Design forsixsigmahas beenakeytothe introductionofnumeroushigh-qualitynew products withsignificantlyenhancedfeatures.”John F. Welch jr.,Ge

18、neralelectricChairmanandChiefExecutiveOfficer,GEAnnual Report2000. bKnowledgeManagementKnowledgeManagementbBusinessResultsOpsReview,StrategyReviewLeadershipValues, Vision,MissionLearningandGrowthStrategyManagementBalancedScorecardProcessManagementCustomerManagementKnowledgeManagementQuality Manageme

19、ntQMSTheSix Sigma SystemCustomersRequirementsSatisfactionCustomersContinuous improvement ofthequalitymanagement systemManagementresponsibilityResourcemanagementProductrealizationMeasurementanalysisandimprovementProductInputOutputSixSigmaProcessCustomerSatisfactionIncreaserevenueandprofitIncreasemark

20、etshareDecreasecostQuality ManagementSystem VS SixSigmaQuality ManagementSystemSixSigmaSystemCustomerSatisfactionBusinessObjectivesBusinessStrategyProcessImprovementBusinessGovernance ModelDeliveryReturnRateWarranty$Problem ResolutionNewprodPerformanceCust.SurveyMfgQualitySupplierPerformanceRevenueC

21、ostProfitMarketShareGrowthBusinessResultsAssessmentPDPProduct LCMSupplierDevelopmentPlanningMarketingCustomerServiceManufacturingISO/QS9000ProcessSixSigmaProcessQIASix Sigma Implementation ModelUnderstanding ofSixSigmaProcess(Executive Training)DefineBusinessStrategy(Values,Vision, Mission)AdoptSixS

22、igmaProcessasLong TermBusinessStrategyfor ContinuousImprovement(QMS Process)Develop MeasurementsandGoals(Balanced Scorecard)for theBusinessGapAnalysis(Understandthe strength &weakness),AreasforImprovementDevelop Business GovernanceModeltoMonitorBusinessPerformanceDefineRoles&Responsibilities forSixS

23、igmaDeploymentDevelop theRoadmap forSixSigmaProcessDeploymentIdentifyResourceRequirementsDevelop SixSigmaGovernance ProcessDevelop SixSigmaTrainingandCertificationprogram (SSL, MBB,BB, GB)IdentifyProjectsforImprovementsAssessBusinessPerformancerelatedtoSixSigmaProcess(QMS Process)QIASix SigmaSixSigm

24、aContinuousImprovementPrioritiesOverall focus will:Dramaticallyreduce theCost of Qualitybyimproving:process improvementproduct andservice improvementdesignimprovementsupplierimprovementtrainingDevelop andimplementasystematic approach to drive performance improvementsthroughout thebusinessMake Custom

25、er Satisfactiona drivingforceinall business decisionsImplementabalancedscorecard thatmeasuresthe successofour effortsLeader/ChampionMasterBlackBelt(MBB)BlackBelts(BB)GreenBelts(GB)Project TeamMembersSixSigma-Roles& ResponsibilitiesIsresponsibleforcoordinating abusinessroadmaptoachieve 6.Selects proj

26、ects,executescontrol,andalleviatesroadblocks forthe 6 projects in hisorherareaofresponsibility.Ismentor, trainer, andcoachofBlackBeltsandothers in theorganization. Bringsthebroadorganization up to therequired6competency level.Isa leaderofteamsimplementingthe 6 methodology on projects.Introduces them

27、ethodologyandtoolstoteammembers andthebroaderorganization.Deliverssuccessful small,focused departmentalprojectsusingthesuccessstrategy.Participatesonthe projectteams. Supports thegoalsoftheproject,typically in thecontext of hisorherexistingresponsibilities.Isexpectedtocontinuetoutilizelearned 6 methodology andtoolsaspart of hisorhernormal job.QIAcan hel