Transcript OSSS Process Member Class Presentation Ph A

Process Management
Training Materials
OSSS LSS Black Belt v9.0 - Control Phase
Copyright Open Source Six Sigma, Inc.
1
Project Management
Course Contents
Class Presentation
• 352 slide PowerPoint Presentation
• Instructor Notes
• 14 Templates
OSSS LSS Black Belt v9.0 - Control Phase
Copyright Open Source Six Sigma, Inc.
2
Project Management
Course Contents
Phase A- Introduction; Define and Measure
Course Overview
• Process Management
• Basic Statistics
• Cost of Poor Quality
• Define Phase
• Defining an Improvement Project
• Measure Phase Part One
• Measure Phase Part Two
• X‐Y Matrix Analysis
• Capability Analysis
• Measurement System Analysis
• Process Improvement Project
OSSS LSS Black Belt v9.0 - Control Phase
Copyright Open Source Six Sigma, Inc.
3
Project Management
Course Contents
Phase B – Analyze, Improve and Control
Course Overview
• Introduction
• Defects, Defectives and Opportunities
• Graphical Analysis
• Lean Value Stream Analysis
• Applying the 5S Principles
• Introduction to Improvement Experiments
• Poka‐Yoke Methods
• Statistical Process Control
• Control Charts
• Tracking and Managing a Process
• Finalizing Your Process Project
OSSS LSS Black Belt v9.0 - Control Phase
Copyright Open Source Six Sigma, Inc.
4
Project Management
A SMALL SNEAK PEAK…
OSSS LSS Black Belt v9.0 - Control Phase
Copyright Open Source Six Sigma, Inc.
5
Project Management
Understanding Process Variation
s
Sigma
s
Fact of Nature/Principle Law – No two things are alike;
everything has variation. Too much variation causes
inconsistency, defects and lack of predictability.
Sigma
Sigma is a Greek letter assigned to represent the amount
of variation or inconsistency a measurable outcome
exhibits. It is a universally accepted method for describing
the magnitude of variation.
s
By using a mathematical or analytical approach, Sigma can
be used to quantitatively describe several performance
metrics:
Sigma
1. Measure of quality
2. Measure of variation
3. Measure of capability of a process
Copyright Open Source Six Sigma, Inc.
Project Management
Understanding Process Variation
The X’s (Inputs)
X1
X2
X3
X4
Y = f(X)
The Y’s (Outputs)
Process:
“A Blending
Of Inputs to
Achieve
Some Desired
Output/Result”
Y1
Y2
Y3
X5
1. There are numerous processes within a company to deliver value
to a customer in the form of outputs (results)
2. Outputs can be measured, and measurement creates data
3. By collecting data, you start the assessment of how well a process
performs and how performance compares to requirements
Copyright Open Source Six Sigma, Inc.
Project Management
Understanding Process Variation
The X’s
(Inputs)
The materials
people
equipment
environ.
The Y’s
(Outputs)
The things you measure as an
indication of the success of
the process.
Verified
?
Op i
Op i + 1
Data for
Y1…Yn
X1
Y1
X2
Off-Line
Correction
Analysis
Scrap
Y2
X3
X4
Yes
X5
No
Correctable
?
Copyright Open Source Six Sigma, Inc.
Y3
10.16
10.11
10.05
10.33
10.44
9.86
10.07
10.29
10.36
9.87
9.99
10.12
10.43
10.21
10.01
10.15
10.44
10.03
10.33
10.15
10.16
10.11
10.05
10.33
10.44
9.86
10.07
10.29
10.36
CTQ = Critical to Quality:
Any output variable of a
process which exerts an
undue influence on the
success of the process or
on meeting customer needs
Project Management
Understanding Process Variation
The Y’s
(Outputs)
Y = f(X) (Process Function)
Verified
?
Op i
Op i + 1
Data for
Y1…Yn
X1
Y1
X2
Off-Line
Correction
Analysis
Scrap
Y2
X3
X4
Yes
X5
Variation – “Voice of
the Process”
Frequency
The X’s
(Inputs)
No
Y3
10.16
10.11
10.05
10.33
10.44
9.86
10.07
10.29
10.36
9.87
9.99
10.12
10.43
10.21
10.01
10.15
10.44
10.03
10.33
10.15
10.16
10.11
10.05
10.33
10.44
9.86
10.07
10.29
10.36
9.80 9.90 10.0 10.1 10.2 10.3 10.4 10.5
Average
(Mean)
Correctable
Critical X(s):
Any variable(s)
which exerts an
undue influence on
the important
outputs (CTQ’s) of a
process
Copyright Open Source Six Sigma, Inc.
Frequency
?
9.80 9.90 10.0 10.1 10.2 10.3 10.4 10.5
Project Management
Understanding Process Variation
Average (Mean)
Point of inflection
There is a standardized
way or a single number
that is used to express
the amount of variation
that exists. It is called the
Standard Deviation or
sigma.
s
-6
-5
-4
-3
-2
-1
+1 +2 +3 +4
This is the
mathematically precise
way of calculating this
value:
+5 +6
s quantifies the spread (around the mean) of a
process or product characteristic.
Copyright Open Source Six Sigma, Inc.
By now we understand
that variation exists in
everything.
n

i 1
(x i  x) 2
n  1
Project Management
Sigma Score – Standard Deviation
At the point of
inflection it is
neither concave
or convex
Average (Mean)
Point of inflection
This part of the
curve is concave
down
This part of the
curve is concave
up
s
-6 -5 -4 -3 -2 -1 +1 +2 +3 +4 +5 +6
Copyright Open Source Six Sigma, Inc.
This is a mathematically precise
and calculable spot that exists
on a normal distribution of data.
Its distance from the mean is the
value of Standard Deviation, it
represents the spread of the
data.
Project Management
Sigma Score – Standard Deviation
As the spread of the data (variability) increases from the
item we have measured, we can see that the “point of
inflection” moves further away from the Mean:
Distribution One
Distribution Two
Distribution Three
s s s
The larger the Standard Deviation, the more spread
there is in the data (variability).
Copyright Open Source Six Sigma, Inc.
Project Management
Linking Sigma Score to Standard Deviation
99.7%
95%
68%
Average (Mean)
Frequency
Point of inflection
1s
-6
-5
-4
-3
-2
-1
+1
+2
+3
+4
+5
-6
+6
Sigma (s1 ):This quantity is used to quantify the spread
(around a mean) of some process or product characteristic.
Requirements – “Voice
of the Customer”
Data - VOP
10.16
10.11
10.05
10.33
10.44
9.86
10.07
10.29
10.36
9.87
9.99
10.12
10.43
10.21
10.01
10.15
10.44
10.03
10.33
10.15
-4
-3
-2
-1
Defects
-5
-3
-2
-1
+1
+2
+3
+4
+5
+6
9.70 9.80 9.90 10.0 10.1 10.2 10.3 10.4 10.5 10.6
Percent Composition
Copyright Open Source Six Sigma, Inc.
+3
+4
+5
+6
Process Performance
(Yields & Transactions)
Defects
-4
+2
Sigma’s from the Mean
“Area Under the Curve”
Sigma
-6
+1
USL = 10.44
LSL = 9.96
10.16
10.11
10.05
10.33
10.44
9.86
10.07
10.29
10.36
-5
2
3
4
5
6
Process
Capability
DPM
308,537
66,807
6,210
233
3.4
Defects per
Million
Sigma level: The metric used to indicate the output
performance of a process to some specification.
Project Management
Sigma Score – A Measurement of Capability
Process Performance
Measured in Sigma’s
Sigma
DPM
2
3
4
5
6
308,537
66,807
6,210
233
3.4
Process
Capability
Copyright Open Source Six Sigma, Inc.
Defects per
Million
The outputs of any process can
be assigned a Sigma Score. How
is this done?
You can calculate sigma one of
two ways:
1. By knowing the
variation of the process
output you are
interested in and
comparing it to the
customer’s
requirements.
2. By already knowing the
defective level from
some source of
information.
Project Management
Sigma Score – A Measurement of Capability
Process Performance
Measured in Sigma’s
Sigma
2
3
4
5
6
DPM
308,537
66,807
6,210
233
3.4
Process
Capability
Copyright Open Source Six Sigma, Inc.
Defects per
Million
1. What was the percent defective
from the dice process_______?
2. Translate that value to PPM
using this example as a
reference:
An output is found to be 30%
defective, calculate as follows”
(30%/100%) X 1,000,000 =
.30 X 1,000,000 = 300,000 PPM= A
sigma score of just a little over 2.
3. Estimate the approximate
Sigma Score of your dice roll
performance (See table on next
page).
Project Management
Sigma Score – A Measurement of Capability
Sigma
DPM
Yield
2.0s
2.5s
3.0s
3.1s
3.2s
3.3s
3.4s
3.5s
3.6s
3.7s
3.8s
3.9s
4.0s
4.1s
4.2s
4.3s
4.4s
4.5s
4.6s
4.7s
4.8s
4.9s
5.0s
5.1s
5.2s
5.3s
5.4s
5.5s
5.6s
5.7s
5.8s
5.9s
6.0s
308,538
158,655
66,807
54,799
44,565
35,930
28,716
22,750
17,864
13,903
10,724
8,198
6,210
4,661
3,467
2,555
1,866
1,350
968
687
483
337
233
159
108
72
48
32
21
13
9
5
3.4
69.1462%
84.1345%
93.3193%
94.5201%
95.5435%
96.4070%
97.1284%
97.7250%
98.2136%
98.6097%
98.9276%
99.1802%
99.3790%
99.5339%
99.6533%
99.7445%
99.8134%
99.8650%
99.9032%
99.9313%
99.9517%
99.9663%
99.9767%
99.9841%
99.9892%
99.9928%
99.9952%
99.9968%
99.9979%
99.9987%
99.9991%
99.9995%
99.9997%
Copyright Open Source Six Sigma, Inc.
Process Performance
Measured in Sigma’s
5.6 %
Sigma
DPM
2
3
4
5
6
308,537
66,807
6,210
233
3.4
Process
Capability
Defects per
Million
Project Management