Customer Expectations Standards Certifications Inspections Packaging Others.
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Transcript of Customer Expectations Standards Certifications Inspections Packaging Others.
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Customer Expectations
Standards Certifications Inspections Packaging Others
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Standards
Identify applicable product standards Identify applicable test standards Understand and implement
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Certifications
Quality Management System (ISO 9001:2008) Environmental Management System (ISO 14001:2004) OHSAS 18001:2000 CE Mark
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Inspections
Second party inspection Third party inspection Self inspection
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Packaging
Proper packaging material Export worthy packaging Usage of symbols Counter presence Packaging cost
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Others
Cleanliness Finish Compliance Timiliness Variation
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Methods
Benchmarking Reliability Studies FMEA QFD Six Sigma
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Six SigmaSix Sigma
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What is Six Sigma?
1. Philosophy: We should work smarter, not harder.
2. Business strategy: We gain a competitive edges in Quality, Cost, Customer Satisfaction.
3. Statistical measurement:We measure defect rates in all processes through an expanding statistical concept.
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What is Six Sigma?
Sigma is a statistical measure of variation from the average
For a manufacturing process, the sigma value is a metric that indicate how well that process is performing.
The value of 1 sigma is one standard deviation from the mean.
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Six Sigma Approach
Combines some of the best technique of the past with recent breakthroughs in management thinking and plain old common sense.
The term ‘Six Sigma’ is a reference to a particular goal of reducing defects to near zero.
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Benefits:
The goal of Six Sigma is to increase profits by eliminating variability, defects and waste that undermine customer loyalty.
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Goals of Six Sigma
To achieve Zero Defect (3.4 PPM) in all outputs of the company through:
a) Measurement of defects in six sigma scale
b) Process re-design to improve capability
c) Involvement of all Employees
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Six Sigma Belts:
Black Belt: Someone who either coaches or actually leads a Six Sigma team.Master Black Belt: A person who coaches a large number of Six Sigma teams.Green Belt: Employees who have received basic Six Sigma training.
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Calculating Sigma
Step 1: Calculating Defects per Unit (DPU)
DPU = Total number of defects Total number of units
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Calculating Sigma
Step 2: Calculating Defects Per Million Opportunities for error (DPMO)
DPMO = DPU X 1,000,000No. of opp. for error
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Calculating Sigma
Step 3: Correlate the DPMO to the chart showing correlation between “defects per million opportunities” and sigma levels.
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Sigma and it’s DPMO
Sigma (σ) value Defects per million opportunities
(+/-) 2 308, 537.0
(+/-) 3 66, 810.0
(+/-) 3.5 22, 750.0
(+/-) 4 6, 210.0
(+/-) 4.5 1,350.0
(+/-) 5 233.0
(+/-) 5.5 32.0
(+/-) 6 3.4
SIGMA CONVERSION CHARTSIGMA CONVERSION CHART
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Tolerance
UCL
USL
LCL
LSL
X
+3σ
+6σ
-3σ-6σ
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Case ExampleSTEP
ACTION EQUATION
CALCUL.
1. How many units were put through the Process?
-- 1283
2. How many came out error free?
-- 1138
3. Compute the yield of the process.
step 2/ step 1 0.8870
4. Compute the defect rate. 1 – step 3 0.113
5. Compute the number of potential things that could create a defect.
N number of CTQs (Critical
To Quality parameters)
24
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Case ExampleSTEP
ACTION EQUATION
CALCUL.
6. Calculate the defect rate per CTQ characteristics
Step 4/ step 5 0.0047
7. Compute the defects per million opportunities
Step 6 X 1,00,000
4709
8. Convert the DPMO into sigma value using the sigma conversion chart
-- 4.1 sigma
9. Draw conclusions Slightly above
average performanc
e
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Six Sigma Tools:
There are two six sigma methodologies:
DMAIC (define, measure, analyze, improve, control)DMADV (define, measure, analyze, design, verify)
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Six Sigma Tools:
For existing processesD DefineM MeasureA AnalyzeI ImproveC Control
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Six Sigma Tools:
For new processesD DefineM MeasureA AnalyzeD DesignV Verify
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The Journey
Six Sigma aims at continual improvement through the journey
starting from the existing sigma level, gradually moving towards six sigma
level and beyond.