A brief introduction to Six Sigma

1. A brief introduction to Six Sigma - Data driven problem solving
June 27, 2012
Villads Haar Jakobsen, WTG Platform and Diagnostics
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2. Agenda
• What is it actually
• Purpose of Six Sigma
• Example of a Six Sigma project organisation
• What about all these belts?
• Different Six Sigma methodologies
• DMAIC
• DFSS
• Where could Six Sigma be used at DONG Renewables
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3. What is it actually?
Six Sigma: A Metric
 The "six Sigma level" of a process can be used to express its capability
 How well it performs with respect to customer requirements
 Defects per million opprotunities
Six Sigma: A method
 A well defined process and tool kit used for:
 Product & service improvements
 Design of products and services
Six Sigma: Symbol, value, benchmark or goal
 Greek letter which defines standard deviation in statistics
 Standard deviation is a measure for spread/variation
 The average distance of the data points to the mean
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4. Purpose of Six Sigma
 To reduce variation
 To work with continous improvements
 To reduce cost of poor quality / reliability
 To make decisions based on statistical basis
Release the full potential
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5. Example of a Six Sigma project organization
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6. What about all these belts??
 White belt
 For managers
 What can we gain from six sigma projcts
 How do we understand the language of six sigma
 Yellow belt
 Know the stages in DMAIC
 Understanding of the 7 basic tools and some statistics
 Green belt
 Know about the basic statistical tools used in six sigma
 Six Sigma project manager
 Black belt
 High level of statistical tools used in six sigma
 Six sigma project manager
 Coaching green belts
 Master black belt
 Extensive experience from many six sigma projects
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7. Different Six Sigma methodologies
Six
Sigma
DMAIC DFSS
Improvement methodology Design Methodology
DMADV
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8. DMAIC Process flow and objectives
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9. DMAIC Examples of tools
• Problem statement • Pareto • FMEA • FMEA • Audit plan
• Process map • Histogram • Histograms, • Pugh matrix • SPC
• Fishone diagram • Fishbone Boxplots, Multi- • Project • Hypothesis testing
• Voice of the customer • SIPOC vari charts, main inplementation
• CTQ's • C&E matrix effects plots, • DoE
• Data collection interaction plots, • EVolutionary
plan etc. Operations (EVOP)
• Data quality (MSA) • Hypothesis tests • Process mapping
• Capability analysis • T-tests • Capability analysis
• Process stability • ANOVA
(control charts) • Regression
analysis
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10. What is the project D
Define
 Problem statement
 Define the goals
 What is the cost of the problem
 Who are the stakeholders
 What are the customer requirements
 Ojective statement
How does the existing process work?
 How is the process and the flow
Project charter
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11. Baseline and capability M
Measure
What is the current performance?
 Understand the process behaviour
 Which factors influence the output
 Verify the mesurement system
 Data collection
 Look for patterns
 Calculate the capability
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12. Potential root causes A
Analyze
What are the key root causes?
 Identify sources of variation
 Determine the critical process
parameters
 Develop and confirm theories
using data
y = f (x1, x2, x3 . . . xn)
Critical Xs
What possible solutions have been identified?
 Models with the highest explanatory power
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13. Developement of solutions and implement I
Improve
Evaluate the solutions and optimize choosen solution
 Which solution provides the best output for the customer
 Cost benefit analysis
 Perhaps it is necessary with additional experiments Quality/reliability
 Optmize chosen solution
Implement the solution
Time Cost
 Risk management
 Contingency plan
 Make a pilot project and compare with initial data
 Implement the solution
 Calculate performance (capability)
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14. Sustainable solution C
Control
How do we keep the benefits of the new solution
 Optimize and refine solution
 Make a follow up plan for the implemented solution
 Monitor and control
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15. DFSS
Concept and Detailed product
Charter CTQ's Prototype
design selection design
• Kano/survey • Brainstorming • FMEA • Robust design • Reliability test
• Project management • FMEA screening • Reliability • Taguchi • FMEA
tools • DoE • Robustness • DoE • Simulation
• Project selection • QFD • Risk analysis • Specification design • SPC
• Benchmarking • Benchmarking • Pareto analysis • Work design • Control plan
• SIPOC • Process map • Gap analysis • Machine design
• C&E matrix • Engineering design
• CTQ matrix
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16. Examples of areas where Six Sigma could be used at DONG
Developement/implementation
Within warranty phase Out of warranty phase
phase
• Choose optimum supplier / • Concerns about the life of • Optimize settings
component components
• RCA
• Evaluation of reliability • Compare performance
• Improve processes
• Quality inspection
• When working with experiments (DoE)
• RCA • Life tests – Robustness and Reliability
• Improve processes
• RCA
• Improve processes
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17. Questions?
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18. Back up – Bathtub curve and the Weibull distribution
λ
Infant mortality Normal life phase Wear out phase
Decreasing failure rate Constant failure rate Increasing failure rate
β>5
β<1 β=1 β>3
Time
Up to "5" yrs ≈ 20 ?
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19. RCA – Analysis of life data
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