6σ_concept.pptx
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6σ_concept.pptx
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s61/16LGEConfidentialUnderstanding6(SixSigma)LGElectronics/PCDiv.QAGroupLGEInternalOnlys62/16LGEConfidentialContents.Whatis6activity?
1.Whatarethestatistics?
2.SolutionofthePracticalProblem3.Whatisthe6concept?
4.6Application5.6ActivityProcess6.Comparewithothertools7.6Philosophy.Whyshouldwedo6?
Quality&FailureRate.HowtoLaunch6?
KeyFactorforSuccessof6?
.WhatisRolledThroughputYield?
s63/16LGEConfidential1.Whatarethestatistics?
Population&SampleSamplePopulationN1,000Measure10samples(Spec.:
1004)Youmaysay“ThisPopulationisGoodbecauseallthesamplesdataarelocatedbetweenLSL&USL.BUT,Ifyouestimatethedefectrateusingstatisticalanalysis,thispopulationhastheprobabilityof2.8%defectsperunit.Thenthisis-wecall-“Anepidemic”qualitydefectlevel.Measuringdefectrateonprocessthroughanexpandingstatisticalconcept,wecanusemeasuringprocesscapability.USL(UpperSpecLimit)LSL(LowerSpecLimit).Whatis6activity?
96979899100104101102103Totalinspectionisimpossible!
Statisticalvariables(mean,variance)estimatepopulations64/16LGEConfidentialUSLUSLTUSLUSLTUSLUSLTPrecisebutnotAccurateAccuratebutnotPreciseShiftingtoTarget&ReducingVariationShifttoTargetReducingVariation2.SolutionofthePracticalProblem.Whatis6activity?
Objectof6isShifttoTargetReducingvariations65/16LGEConfidential6QualitymeansthatareaoftheestimatednormaldistributionislocatedbetweenUSL&LSLwith6.Inthatcaseareaoftheoutlierspec.(Inotherwordsestimateddefects)isjust3.4PPM.*:
StandardDeviationStatisticindexmeasureshowmuchdataapartfromtargetvalue3.4ppmTargetUSLLSL+6-6+3-36.68%3.whatisthe6concept?
.Whatis6activity?
StatisticalDefinitionof636s66/16LGEConfidential63.4523346,210366,8072308,537PPM1misspelledwordinallofthebookscontainedinasmalllibrary$340indebtednessper$100millionsassets1.8minutesperyear1.5misspelledwordsperpageinabook$6.7millionsindebtednessper$100millionsassets24daysperyear.Whatis6activity?
6astheBusinessStrategy3.whatisthe6concept?
s67/16LGEConfidentialInallDesign,Manufacturing,andSVCprocessesApplyingfor6statisticTools&ProcessesTofindfactorscausingdefectsActingtheAnalysisandImprovementThroughtheDefectReduction,IncreaseYield&TotalCustomerSatisfactionManagementInnovationToolcontributestoManagementOutputAchieving3.4PPM(3.4DefectsPerMillion)Whatis6activity?
PPM:
PartsperMillion.Whatis6activity?
6astheActivity3.whatisthe6concept?
s68/16LGEConfidential4.6ApplicationSelectingCTQtomeetcustomerneedsDecisionreasonableToleranceGuaranteeoftheCTQscapabilityanalysisImprovementseriousproblemusingS/WRealTimeMonitoringsystemCTQControlsystemImprovementcycletimeandaccuracyCostImprovementGuaranteefortheDesigncompletionindevelopingstageQualityassuranceinmanufacturingstageMaximizingforsales&SVC6isatoolthatappliestoallbusinesssystems-Design,Manufacturing,SalesandSVC.Whatis6activity?
R&D6Manufacturing6De-signSales&SVCMfg.6Transaction6DesignMfg.Sales&SVCs69/16LGEConfidentialIdentifyCustomer-DrivenCTQ(CriticaltoQuality)CharacteristicsIdentifyKeyProcessesthatcauseDefectsinaCTQCharacteristicsForEachProductorProcessCTQMeasure,Analyze,Improve,&Control6isarigorousanalyticalprocessforsolvingproblem!
5.6ActivityProcess.Whatis6activity?
1.Whoareyourcustomers?
-Internal/External2.Whatdoyouprovideyourcustomers?
3.Whatiscriticaltoqualityforyourcustomers?
1.WhatareyourinternalprocessesforprovidingyourproductorserviceCTQstoyourcustomers?
2.Wheredodefectsoccurintheseprocesses?
DDPracticalProblemMeasurementSystemYieldCalculationProcessMappingCalculationBenchmarkingParetoChart&StratificationCause&EffectDiagramDOEBrainstormingActionWorkoutTechniquesPilotingControlMechanismControlChartProceduresMMAAIICC6ActivityProcess(manufacturing&Transaction)*CTQ(CriticalToQuality):
Yourcustomersfeelthatcharacteristicofproduct,serviceorprocessiscritical.*D:
Defines610/16LGEConfidentialExampleofdevelopmentprocessappliedbyR&D6ExampleofdevelopmentprocessappliedbyR&D6R&D6Kick-OffEvaluationmeetingforpresentconditionEvaluationmeetingforbasicconceptEvaluationmeetingforplanningconfirmE/SdrawingconfirmCusto-merNeedsSurveyQFDS-1SpareCTQSelec-tionSimilarprocessDatagatheringZValueofCTQAnalysisMeetingforCTQCheckZValueoptimize,DesignimproveQFDS-2DesignFMEAProcessFMEADevelopmentProcessE/SmakingDevelopmentdrawingconfirmIncomePartsE/SQualitymeetingP/LMakingP/LQualityMeetingIncomepartsP.PMakingP.PQualitymeetingCTQDatafornewpartsgatheringActivityforprocessimprove-mentCTQfornewpartsConfirmCTQdeci-sionZValueofCTQconfirm5.6ActivityProcess.Whatis6activity?
s611/16LGEConfidential-Define/Measurement-VarianceofCTQ-Presentcon-ditionAnalysis-ImprovedbyexpertsIdea-Controledbycontrolchart-Process4McontrolMeasure-Symptoms-Frequency-Analysisforstatistics-Effectanalysiscausedfactors-OptimizingconditionbystatisticalanalysisOthers6-DiscreteData-Difficulttoapplypracticalproblembecauseofcomplexity-Discrete+Continuousdata-Easytoapplybecauseofsupportingstatisticalsoftware.AnalysisImprovementControl-ControledbyPTS(CTQ,Benefits)Focusingexperience/technology*PTS:
ProjectTrackingSystem*ByImprovementProcess.Whatis6activity?
6.Comparewithothertoolss612/16LGEConfidential6.ComparewithothertoolsDetectingprocessdefectsProductmanagingcomparewithspec.JudgingeachpersonsKnow-HowManualDatagathering&analysisControlprocessvariationJudgingthestatisticDataSimple&EffectiveanalysisusingtheS/WPreventionControlvitalfewfactorsManagingToolImprovementToolSelectingLineDoprocessFMEA-SelectingCostissueprocessviewofcustomerConformCTQprocessSortingtheprocess-Justneedcontrolprocess-Importantcontrolprocess-Lawapplicationprocess-Variationimprovement100ppm/6applicationaccordingtosortingprocess100ppm/6.Whatis6activity?
100ppm6100ppm/6Applications613/16LGEConfidentialWedontknowwhatwedontknow.Ifwecantexpresswhatweknowintheformofnumbers,wereallydontknowmuchaboutit.Ifwedontknowmuchaboutit,wecantcontrolit.Ifwecantcontrolit,weareatthemercyofchance.7.6Philosophy.Whatis6activity?
s614/16LGEConfidentialOursurvivalisdependentupongrowingthebusiness.Ourbusinessgrowthislargelydeterminedbycustomersatisfaction.Customersatisfactionisgovernedbyquality,price,anddelivery.Quality,price,anddeliveryarecontrolledbyprocesscapability.OurProcesscapabilityisgreatlylimitedbyvariation.Processvariationleadstoanincreaseindefects,cost,andcycletime.Toeliminatevariation,wemustapplytherightknowledge.Inordertoapplytherightknowledge,wemustfirstmeasureit.Measuretheproblem,wellgettherightknowledge.Whatis6activity?
7.6Philosophys615/16LGEConfidential“GenerallycontrolledF-CosthassmallportionconsideringofHiddenLoss”TraditionalF-Cost(EasyDefinition)InspectionScrapReworkRejectSVCLossOpp.SalesDeliveryDelayBrandImageDownOfficeLossOverStorageOverReworkLongcycletimeDesignChangePotential(Additional)F-Cost(Difficulttomeasure).Whyshouldwedo6?
Quality&FailureRates616/16LGEConfidentialKeyFactorforSuccessof6NeedTopDownDriveNeedTopmanagementsstrongwillfor6.Topmanagementsstrongandperiodicalannouncementabout6policy.Allemployeesmustparticipate.Notonlymanufacturingpart,butalsonon-manufacturingpartshouldjointheprogramFocusonCustomersrequirements.6asPan-Companyscommonstandard.Commonlanguage.(CTQ,Cp,Z.)Avoidpersonaltranslationabout6.AllofGoalandtargetarerepresentedasscale.Basicprocessforallofprojects.HowtoLaunch6?
StartatCustomersvoice.CTQsfromCustomersvoice,Improvetheitemwhichhasbigimpactfirst!
NeedTrainingProgramforAllemployeesCompleteunderstandingfor6program.Hardtrainingforallemployees.Needresourceinvestmentresolutely.ConstructInfraNeedsuccessfulcasestudyproject.Resourcereformationfororganizationandsystem.Reasonableappraisalandrewardsystem.SystemrequirementMethodologys617/16LGEConfidential.WhatisRolledThroughputYield?
Rolledthroughputyieldisprobabilityratiotoacceptforallprocesses.FinalGoodProcessDefectRatioLossbyun-controlInputProcess1:
99%AcceptratioProcess2:
92%Process3:
93%FinalInspection:
97%RTYControlProcessdefectratioControl*RTY:
RolledThroughputYieldRTY=0.99X0.92X0.97X0.97=85.7%ObjectProductivityelevationthroughqualityimprovementApplyDefectofallprocesses,EquipmentModelChangeLossTool6Method1person1Project,TeamactivityAddedImprovementforhiddenfactory
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