Six Sigma Overview Flashcards
80’s Quality Breakthrough
the realization by management that the processes, not the people, are the key to error free performance
ISO 9000
- International Organization for Standardization
- focus on documentation of standards and procedures
- requires “you do what you say you will do”
- can be costly to implement
- prestigious to be considered certified
Malcolm Baldrige
- National quality award
- focus on overall business excellence
- criteria for evaluation: leadership, strategic planning, market focus, information/analysis, human resources, process management, results
TQM
- management philosophy
- emphasized commitment to excellence
- teaching of Deming (adopted early by Japanese)
- 14 points of management
Lean Thinking
- TPS
- focuses on waste reduction (7 types)
- emphasizes visual change
- kaizen quick hits
5 basic principles of lean thinking
- specify value
- map the value stream
- improve flow
- allow customer pull
- pursue perfection
TPS - main people, established what, did what for america
- Taiichi Ohno and Shigeo Shingo
- synchronized supplier process to establish JIT
- benchmarked supermarket processes in America
- spread to non-manufacturing processes
International Motor Vehicle Program (MIT)
- Lean
- Jim Womack / Daniel Jones
- “the machine that changed the world”
- TPS vs. Mass production
- termed toyota as the “birthplace of lean”
what is lean?
- John Shook - “A manufacturing philosophy that shortens the time line between the customer order and the shipment by eliminating waste.”
a systematic approach to identifying and eliminating non-value-adding activities in the healthcare delivery process, enabling care to flow more effectively
the principles of lean production include…
- efficient use of resources and elimination of waste
- teamwork
- communication
- continuous improvement
Steps/tools in Lean
- waste identification
- takt time calculation
- kanban sizing
- 5S
- visual factory
Lean results
- reduced cycle times
- improved promises kept
- reduced WIP inventories
- flexible workforce
- the space
Six Sigma characteristics
- driven by voice of the customer
- rigorous 5-phase approach
- data driven approach
- focuses on defect reduction
- reduces process variation
- requires leadership commitment
What is the goal of six sigma?
- quantitatively, this means the average process generates less than 3.4 defects per million
- culturally, this means we need to learn how to be nearly flawless in executing our key processes
What is six sigma?
- process to reduce defects per million opportunities (DPMO)
- a statistic that measures how close we are to our goal
- a methodology focused on continuous improvement
Stephen Covey’s 7 habits of highly successful people - which quadrant does six sigma fit in?
the second quadrant (important and not urgent
What are 2 important measurables that affect the customer?
CTQ and VOC
CTQ
critical to quality - the big Y
Process entitlement
what your process can deliver to the customer
the “fruits of six sigma”
- sweet fruit: design for six sigma
- process entitlement at the top
- bulk of fruit: process characterization and optimization
- low hanging fruit: seven basic tools
- ground fruit: logic and intuition
Champions
champion-trained business leaders who lead the deployment of six sigma in a significant area of the business
master black belts
fully-trained quality leaders responsible for Six Sigma strategy, training, mentoring, deployment, and results - A CERTIFIED BLACK BELT, THATS ALL THEY DO
black belts
fully-trained six sigma experts who lead improvement teams, work projects across the business and mentor green belts - FULL TIME IE PROBLEM SOLVERS
green belts
fully-trained individuals who apply six sigma skills to projects in thier job areas (process manager) - LEARN TOOLS, BUT NOT THIER FULL TIME JOB
process owners
provides direction and leadership for the process. ensure process improvement efforts have needed resources. leader of solution implementation
finance rep
responsible for independently validating financial results - provides definition to savings categories
Define Phase keys
- problem statement
- objective statement
- project charter
measure phase keys
- detailed process flow diagram
- measurement system analysis
- beginning project capability
Understanding varation: traditional philosophy vs taguchi philosophy
- traditional: anything outside the spec limits represents the quality losses
- taguchi: any deviation from the target causes customer loss
the higher the number (Z) in front of the sigma symbol….
the lower the chance of producing a defect
Six sigma is…
+/- 6 sigma, NOT +/- 3 sigma
Analyze Phase Keys
- what are the most likely causes (the vital few vs the trivial many) and how do you know
- identifying the trivial many X’s
- narrowing down to the vital few
- graphical/statistical analysis
improve phase keys
- understand root cause
- discover f(x) relationship
- run pilots
- estimate expected impact
Control Phase Keys
- control the X’s
- monitor the Y’s
- establish plan for sustainability
- update benefit estimate
- transition to process owner
how can we sustain the solution so that the problem stays fixed permanently?
- mistake proofing
- robust design
- control charts
Lean vs six sigma (focuses)
- lean: waste reduction (reduce cycle times, reduce inventories, value stream, flow focused visual change)
- six sigma: defect reduction (VOC, process capability, graphical/statistical tools, control plans)
