Six Sigma 12 Steps (六西格玛的12个步骤).pptx
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Six Sigma 12 Steps (六西格玛的12个步骤).pptx
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MethodologyOverviewPhaseII:
ProcessMeasurementPhaseIII:
ProcessAnalysisPhaseIV:
ProcessImprovementPhaseV:
ProcessControlSixSigmaPhasesPhaseI:
ProcessDefinitionMAICDSUPPLIERProcessStep1Processstep2CUSTOMERProcessstep3RECORDDEFECTSRECORDDEFECTSRECORDDEFECTSRECORDDEFECTSRECORDDEFECTSMEASURECONTROLIMPROVEANALYZECONTINUOUSIMPROVEMENTMODELPROCEDURETIMEGOALTRENDCHARTACTIONPLANACTIONNAMEDATEVitalFewIdentificationContinuousImprovementThefollowingvisualillustrateshowthesystemcanworkDEFINESixSigmaBreakthroughStepsDefineMeasureAnalyzeImproveControlStep1-SelectOutputCharacteristic-IdentifyProcessInput/OutputVariablesStep2-DefinePerformanceStandardsStep3-ValidateMeasurementSystemStep4-EstablishProcessCapabilityStep5-DefinePerformanceObjectivesStep6-IdentifyVariationSourcesStep7-ScreenPotentialCausesStep8-DiscoverVariableRelationshipsStep9-EstablishOperatingTolerancesStep10-ValidateMeasurementSystemStep11-DetermineProcessCapabilityStep12-ImplementProcessControlsSixSigmaMethodologyStep1-DefinePhaseStep1-DefinePhaseYouhavetohaveareasontodoaprojectandthatreasonshouldbesomethingthatisbotheringacustomer.Ifyoucantidentifywhatisimportanttoworkon,dontworkonanything.Ifyoucantputanameonityoucantdoit.Ifyoucantdefinetheunitsofmeasure-becareful!
Youwillenduphavingto:
Definetheunitsofmeasureandcreateameasuringsystemfortheissueatthebeginningofyourproject.Step2-MeasurePhaseStep2-MeasurePhaseIfyoudontknowwhatmakessomethinggoodorbad,howcanyoumeasuretheproblemintermsofdefects(DPMO)?
Ifthedefinitionofwhatmakesadefect(thespecification)isnotinthesameunitsofmeasureastheselectedYfromstep1,youhavethewrongspec.ThedefinitionneedstobecrystalclearandbriefSelecttheOutputCharacteristic(the“Y”)Whatistheproblem?
Whatisadefect?
DefinethePerformanceStandardofthe“Y”Whatisthespecificationorlevelofperformancerequiredbythecustomer?
SixSigmaMethodologyStep3-MeasurePhaseStep3-MeasurePhaseIfyoucantmeasuresomething,howdoyouknowwhereyouare,whereyouhavebeen,orwhereyouaregoing?
Ifyourmeasurementsystemisincapable,STOPandFIXITbeforeproceedingIfyourmeasurementsystemisincapable,STOPandFIXITbeforeproceeding.Note:
MeasurementSystemAnalysis(MSA)mustbedoneonanyandalldefectsyouwishtocount(watchoutifyouhaveavisualinspectionof6characteristics)Step4-MeasurePhaseStep4-MeasurePhaseIknowwhatIwanttofix(step1),whatdefinesitasgoodorbad(step2),andIcanaccuratelymeasureit(step3)so:
NowIcansayhowmyprocessisperformingintermsoflongandshorttermZandDPMOwhichismybaselinedefectrate.Iknowcanimprovefromhere.ValidatetheMeasurementSystemCanweaccuratelyandconsistentlymeasuretheY?
Canyoutrustyourdata?
EstablishProcessCapabilityWhatisourdefectratetoday?
SixSigmaMethodologyStep5-MeasurePhaseStep5-MeasurePhaseWheredoIwanttobeattheendofmyproject?
Thereshouldbeastretchgoalwithlogicbehinditsselection.Theobjectiveshouldmakeitcleartoallatwhatpointtheprojectwillbeconsideredcompleteandsuccessful.Step6-AnalyzePhaseStep6-AnalyzePhaseDefinePerformanceObjectivesGiventhecurrentdefectrate,howmuchshouldweexpecttoimprove?
IdentifyVariationSources(“Xs”)Whataresomepotentialcausesofthedefect?
Listallpotentialinputs(KPIV,X)thatcouldaffectmyoutput(KPOV,Y).Thisisfillingthetopofthefunnel.Sometoolsincludefishbone,C&Ematrix,FailureModesandEffectsAnalysis(FMEA),detailedprocessmaps.Thinkoutsidethebox-ifyoufixitthesamewayyoudidlastyear,youwillhavethesameproblemyouhavenow.SixSigmaMethodologyStep7-AnalyzePhaseStep7-AnalyzePhaseStep8-ImprovePhaseStep8-ImprovePhaseScreenPotentialCausesCanIfigureoutwhichofthepotentialcausesareactuallyaffectingmydefectrateusingstatisticaltests?
ScreeningisdoneusingGraphicalToolsandHypothesisTeststoidentifyandprovewhicharethevitalXs.ThisisthemiddleofthefunnelforprojectswithvariablerelationshipsbetweenXsForsomesimplerprojectswheretherearenovariablerelationshipsbetweenmyXs(orIhaveonly1X)thisisalsostep8thebottomofthefunnel,thefinalvitalXsDiscoverVariableRelationshipsNowthatIknowwhichonesactuallycausethedefect,howshouldtheybesetsotheyproducetheleastamountofdefects?
EvaluateifanyofmyvitalXsareaffectedbyotherVitalXs.ThisisprimarilydonethroughtheuseofDesignofExperiment(DOE)formoderatetocomplexprojects.DOEisanexperimentalprocessthatdeterminestheimpactofmultipleinputsonaselectedoutput.Thisleadstothebottomofthefunnel,IknowwhichXsaffectmyYandhowtheyaffecteachother.Transactional-useOFATapproach.SixSigmaMethodologyStep9-ImprovePhaseStep9-ImprovePhaseStep10-ImprovePhaseStep10-ImprovePhaseIknowwhichXsareimportant.WhatrangeofsettingscanIusetomakegoodproduct?
InthecaseofavariableX(e.g.PSIonanairfeed),Ihavetoprovideasettingtolerance.EstablishOperatingTolerancesCanIestablishatoleranceformyinputsthatwillstillyieldalowdefectratetoleavemyselfsomeflexibilityandfacilitatecontrol?
ValidateMeasurementSystemNowthatIhaveimproved,canIstillmeasurethedefectorthecausesgoingforward?
InthecaseofavariableX(e.g.PSIonanairfeed),Ineedtovalidatethatitcanbemeasured(avitalXMSA).Also,ImighthaveimprovedmyYsomuchthatIcannolonger“read”myprocess,andmayhavetoimprovemygagesystemtotrulymeasurewheremyimprovementshavebroughtme.SixSigmaMethodologyStep11-ImprovePhaseStep11-ImprovePhaseStep12-ControlPhaseStep12-ControlPhaseDetermineProcessCapabilityWhatisthedefectratenowthatIhaveimplementedtheimprovements?
ThismeasuresthecapabilityofcontrollingmyXswhereIhavesetthem.Thisisalsothetimewhenwedetermineformalresultsbycomparinganewcapabilityanalysiswiththebaselinecapabilityanalysis(step4)andourgoals(step5).ImplementProcessControlsHowdowemakesureitstaysfixed?
TheXsyouhavedeterminedasvital,theirsettings,andotheractionsyouhavetakentomaketheimprovementmustbe:
NaileddownSetinconcreteFullyimplemented(NOTjustagreedto)PutintoarigorousauditscheduleBEFOREyoucansayaprojectisclosed!
AdvancedToolsYIELDAcceleratedResultsFivePhasesandKeyToolsControlPlanSPCMistakeProofingAutomatedControl$MeasureAnalyzeImproveControlMetricsGageStudiesCapabilityProcessMapC&EMatrixFMEAMulti-VariHypothesisTestingANOVAVariationTreeDOE:
FullFactorials2KFactorialsFractionalFactorialsDefineOutputCharacteristicsOutputVariables六西格玛的12个步骤1选择输出特性2定义绩效标准3确定量测系统4确定生产能力5定义绩效目标6定义变化来源7筛选可能因素8发掘变量之间的关联9定义操作公差10验证量测系统11验证过程生产能力12执行过程控制步骤1-选择输出特性你的每一个项目都应有一个开始的理由,这个理由应该是令你的客户感到不方便的事情。
如果你不能够找出有什么重要的事情,那就什么也不要做。
如果你不能给项目一个执行的理由,那就不要执行它如果你的项目没有一套绩效评估的依据,或是在项目完成时你无法衡量完成的好坏,那你应在项目开始时就建立一套绩效评估的标准。
步骤2定义绩效标准(工程标准)如果你不知道什么产品是合格的,什么是不合格的,那你如何统计不良品的发生率(DPMO)如果在工程标准中对于不合格品产生的原因与步骤1中所选择的客户质量统计中不一致,这说明你使用了不恰当的工程标准定义标准必须完全清晰简洁步骤3确定量测系统如果你不能进行测量工作,那你怎么知道你当前工作的进程,你取得了什么成绩,及你目前所处的位置如果你发现你所使用的量测系统存在缺陷,在继续使用前应马上停止使用这套系统,立即改正缺陷注:
MSA应有能力统计你希望统计的所有疵点数量步骤4确定生产能力我知道我的目标是什么(步骤1),判定合格或不合格的标准(步骤2),同时我有能力精确的测量它(步骤3)所以:
-现在我可以确定我的项目将会取得的短期和长期的Z值和DPMO值-我从这里开始改进通用工具,六西格玛“过程报告”用于连续型数据&“产品报告”用于离散型数据。
步骤5定义绩效目标我希望这个项目最终取得什么成果?
选择这个项目应有充分的理由。
步骤6确定变化来源列出所有可能影响你的输出特性(KPOV,Y)的潜在输入特性(KPIV,X)这是烟囱图的最顶端鱼骨图、C&E图,FMEA,过程流程图等工具发散思维,如果你按照去年解决问题的方法解决这个问题,那你以后还会遇到相同的麻烦步骤7筛选可能因素使用图形工具和假设分析,寻找并确认关键输入特性X。
对于一些项目来说,这只完成了一半任务,但对一些较简单的项目来说,这些工作能说明在输入特性之间有无关联(或者只有一个输入特性X)这正是步骤8要分析完成的,寻找到关键输入特性X。
步骤8确定变量之间的关联发掘关键输入特性之间是否有相互作用。
不论是何种项目,通常都采用DOE分析方法完成任务这将指引我们完成分析,我不仅知道输入特性X是如何影响输出特性Y,我也知道输入特性之间的关系步骤9定义操作公差我知道哪些输入特性是重要的,针对项目何种设置是合适的在输入特性X的允许变化范围内(例如空气压力PSI值),必须提供操作公差步骤10验证量测系统在输入特性X的允许变化范围内(例如空气压力PSI值),我必须证明此特性可以被测量,提供操作公差(一个关键输入特性X的MSA)同时,如果输出特性Y经改进后的值超出了我目前使用的测量系统的测量能力,我应改进我的量测系统,以确保得到真实的改进后的结果步骤11-验证过程能力测量所能够控制输入特性X的能力通过将新的生产能力分析与原来的生产能力分析(步骤4)和我们的目标(步骤5)进行比较可以得出正式的结果通用工具,6西格马“过程报告”用于连续型数据&“产品报告”用于离散型数据步骤12-执行过程控制在你的项目完成前,你应将改进的输入特性X值及其它有助于问题改善的措施都固定下来,书面化,全面落实实施(不能不能只是口头答应),同时最好建立一套严格的监督体制
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