Six sigma cmm levels style design 5 powerpoint presentation slides.
Six Sigma Lesson (Powerpoint)
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Transcript of Six Sigma Lesson (Powerpoint)
Six Sigma – What is it?
Six Sigma
What is it?
Robert Fruit SSBB CQE
Six Sigma – What is it?
Page I – 2 Guaranteed Success
Six Sigma – What is it?
Page I – 2 Define the Problem
Six Sigma – What is it?
Commercial Airline Take Off• Pilot walks around the plane
– Alaska Air – plane crashes because of failed cable to vertical stabilizer
• Pilot checks controls from cockpit– United Air Lines plane runs out of fuel when captain
asked for gallons of gas and was given litters of gas
• Pilot goes through lengthy check list– All procedures have historical reasons– Have some procedures outlived their usefulness
• This procedure has 6 level of success, it is not Six Sigma
Six Sigma – What is it?
Six Sigma is a Process for Improvement
• Six Sigma is different than the procedures that preceded it
• Emphasizes that you must have top management involvement from the start
• Always has a limited time frame
• Has a written goal
• Has determined a means to measure success
Six Sigma – What is it?
DMAIC • Define
• Measure
• Analyze
• Improve
• Control
Six Sigma – What is it?
Six Sigma is about Measuring
Six Sigma is all about measuring to prove results and improved profit. It is also about shaking things up. An organization not willing to change is not prepared to start a Six Sigma project
Six Sigma – What is it?
Make no Arbitrary Decisions
• Six Sigma is based on measured values
• Many of those measurements are statistical
• “… there are many degrees of probability, some nearer the truth than others …” – Christian Huygen 17 century from– Absolute Zero, Shachtman, 1979
Six Sigma – What is it?
Not every problem is a Six Sigma issue
• Daily issues are no Six Sigma issues
• Opened ended problems are not Six Sigma issues
Six Sigma – What is it?
Six Sigma issues have defined periods
• Part of defining a Six Sigma issues is setting a time limit for the Six Sigma effort.
• Typical time period is 3 months
• Some have less time
• Rarely does a Six Sigma effort have more than 9 months
Six Sigma – What is it?
Where to Start• Look for KIPV (Key Input Variables)
• That effect KOPV (Key Output Variables)
• KIPV
• Things that influence KOPV
• KOPV
• Things that are important to your customers
Six Sigma – What is it?
Voice of the Customer
• KOPV – is the voice of the customer
• If it is important to the customer it is a KOPV– Appearance– On time delivery– Meet its requirements– support
Six Sigma – What is it?
Who is the customer
• The person outside your company who buys your product
• The person inside your company who uses your product next
• Both
Six Sigma – What is it?
The Purpose of Business
• Take a product
• Perform your procedures on it
• Increase the value of the product
• Have a customer (internal or external) who is willing to buy that increase value
Six Sigma – What is it?
Where did Six Sigma Begin• Motorola made Quasar TVs in Chicago
– Lost money on every set that left the plant– Problems with quality of sets– Problems with worker motivation
• Sold Manufacturing plant to a Japanese firm– Got workers involved in manufacturing process– Reduce defect to 1/20 of former level– Same plant, same workers– Made big profits
• Motorola was embarrassed– CEO swore never to let this happen again– Started people on the path that became Six Sigma
Six Sigma – What is it?
GE gets into Six Sigma
• Under Jake Walsh GE starts to use Six Sigma methods
• One of the biggest money savers was in reports.– People went around and talked to managers about
the mountain of reports they got every month– Found that only a few of the reports were actually
used– Eliminated unused reports– Estimated savings about $1 billion per year
Six Sigma – What is it?
TQM• Who remembers TQM• It tended to be a top down system• Upper management demanded better quality
from the people who worked for them• Who remembers “Quality is our business”• TQM tended to be short term attention
– As soon as quality problem solved move onto next project
– Lack of follow up
Six Sigma – What is it?
Six Sigma is Long Term
• Get top management involved from the beginning
• Clearly define the problem• Measure performance• Measure results of improvements
– Report on $$ saved by improvements
• Set up system to monitor results after project is concluded
Six Sigma – What is it?
The Cost of Poor Quality
• Many companies operate at 3-4 levels• 25%-40% of revenue used for fixing defects
– Rework parts– Sorting out defective parts– Scrape– Extra employees
• Most of these companies don’t realize what poor quality is costing them
• Companies working at 6 level typically spend 5%
Six Sigma – What is it?
Probability and Central Tendancy
• Typical show single probability curve
• The central tendency can shift from the ideal position
• This increases the area in the tail regions which is a measure of defects
Six Sigma – What is it?
Six Sigma Defects per Million
• Allow the central tendency move by 1.5 standard deviations either side of theoretical perfection– Page II-3
Six Sigma – What is it?
Defects per Million Opportunities
• DPP – Defects per part– DPP = defects / parts
• O – Number of opportunities for a defect per part
• DPMO = DPP / O * 1,000,000
Six Sigma – What is it?
Six Sigma – 3.4 DPMO
• Achieving Six Sigma level is having 3.4 DPMO
• Measure defects at start of process– Convert to level
• Measure defects after improvement– Convert to level
Six Sigma – What is it?
Six Sigma is more than DPMO
• DPMO in manufacturing• DFSS – Design for Six Sigma
– New process designed to meet Six Sigma from the beginning
• Lean Manufacturing• In general almost anything that significantly
improves profits
Six Sigma – What is it?
Punch Press Problem• Bid on project based on 100 parts per minute• Best they can achieve is 80 parts per minute• They were going to loose a lot of money on the 3
year contract
Six Sigma – What is it? Hand placed
• The pieces over lap each other• Must be precisely placed for machine
pickup at customer• NO DEFECTS allowed in trays
Six Sigma – What is it?
80 Pieces Per Minute• Punch press no defective parts• Operators must untangle parts on round table• Operators barely keep up with flow of parts• Unstack tray for parts
Six Sigma – What is it?Process FlowchartPreliminary Flowchart - Six Sigma Project Wauconda Tool & Eng.
10 20 30 40 50 60 70
Lead Frame Packaging
Flow
Receive Trays
Deliver to Press
Unpack Trays
Stage TraysPack
parts in Trays
Place 19 trays per box (54
parts/tray
1) Tape box 2)Part on Skid 3) Add Control tape
10 20 30 40 50
Stamping Flow
Retrieve coil from
stock Coil
Deliver two coils to press
Feed coil to press
1) Feed coil 2) Stamp 3) QA Check
Stamp Parts
10 20 30 40
Terminal Packaging
Receive boxes
Deliver to Press
Bulk Pack
1) Tape Box 2) Color code Tape
Send to Shipping
Saturday , January 7,2006
Quantity by Press count
Six Sigma – What is it?
Things Under Consideration
• Process Issues– Improving manual packing methods– Un-stacking of delivered trays– Running machine at 180 SPM– maintain current quality– Using 2 inch or 3 inch stroke press– Staging and storage of trays– Analyzing cost of materials
Six Sigma – What is it?
Change Packing
• Receive 1,000 trays to a box– Hard to unpack from shipping box– Trays cling together– Must be separated without distorting box– Come from Phoenix
• Send 16 trays out in special boxes• Arrange for local manufacture of trays
– Receive in the same boxes used to ship product
Six Sigma – What is it?
Change Personnel Layout• Tests showed that packers on linear
conveyor packed faster– Parts did not stack on each other
2
1 4
3
2
31
4
Original personnel layout
Improved personnel layout
Six Sigma – What is it?
Original Costs80 Strokes/Minute Cost/K % TCMaterial Cost $105.89Scrap Reclaim -$57.94Total Mat'l Cost $47.95 42.2%Processing Cost $25.56 22.5%Packaging Material $9.22 8.1%Packaging Labor $23.11 20.4%Set-up Cost $0.32 0.3%
Changeover Cost $0.32 0.3%Die Maintenance Cost $7.05 6.2%
Total Cost $113.5280 100.0%
Six Sigma – What is it?
Improved Costs180 Strokes/Minute Cost/K % TCMaterial Cost $105.89Scrap Reclaim -$57.94Total Mat'l Cost $47.95 48.3%Processing Cost $11.36 11.4%Packaging Material $9.22 9.3%Packaging Labor $23.11 23.3%Set-up Cost $0.32 0.3%Changeover Cost $0.32 0.3%Die Maintenance Cost $7.05 7.1%
Total Cost $99.3280 100.0%
Six Sigma – What is it?
Improved ProfitsTotal Cost w/ Recommended Changes $81.2680Total Cost Now $113.5200Savings per Thousand -$32.2520Year 1 Savings (1.8M) -$60,311Year 2 Savings (4.3M) -$154,165Year 3 Savings (9.3M) -$300,589Total Three Year Savings -$515,064
Six Sigma – What is it?
Some Keywords
• DMAIC
• Voice of the Customer
• KIPV
• KOPV
• DPMO
Six Sigma – What is it?
High Definition Television
Six Sigma – What is it?
HD TV on a computer• ATI makes a HD tuner for PCI slot – HDTV
Wonder
• Works only with broadcast HD signal
• Minimum standards do not come close to describing computer requirements
• Do not get without having AGP 8x or PCI express slot
• Designed to be part of multi-media computer
• Has remote control, USB plug in receiver
Six Sigma – What is it?
Extreme Tech Comment
The card itself features a Philips HDTV tuner box but ATI’s NXT2004 receiver chip does much of the heavy lifting. The NXT2004 VSB (vestigial sideband modulation)/QAM (quadrature amplitude modulation) Receiver is designed for off-air and cable digital television receivers, set-top boxes, PCDTV, and datacast applications where cost, low power and industry-leading performance are a must. The NXT2004 Multimode VSB/QAM demodulator can work in either the ATSC compliant 8 VSB mode for terrestrial broadcasting, or DICSIS-compliant 64 QAM or 256 QAM modes for Digital TV-Cable Connect and Digital TV Cable Interactive reception. However, in the HDTV Wonder product, the NXT2004 is set up only as a 70-channel off-the-air HDTV receiver
Six Sigma – What is it?
ATI HDTV Card
Six Sigma – What is it?
HDTV is not CPU hog• 2.8 G-Hz celeron• 768 Meg Ram• 7200 RPM HD• No AGP• No PCI express• 720P – black image• 1080i – black image• Demand Direct X 9
– Plus more
Six Sigma – What is it?
ATI RADEON 9250 PCI
Six Sigma – What is it?
Things I have Learned• If you go for HDTV Wonder you are still in the pioneer era
(arrows in the back)• The card assumes you are creating a media computer (rich set
of software features)– Remote control plus USB RF receiver– Needs tweaking to start HD TV– S video and component Video, left, right input
• Not every feature works as well as you would like– TV directory– Create DVD disk
• Keep it all ATI (HDTV and video card)– Complaints about GE-Force video cards
Six Sigma – What is it?
And now to Robts• There are children ready
robot projects
• No not the False Maria
• Based on BASIC Stamp module
Six Sigma – What is it?
2 Robots
Six Sigma – What is it? BASIC Stamp
5V RegulatorRegulates voltageto 5V with a supply of 5.5VDC to 15VDC
ResonatorSets the speed at whichinstructions are processed.
EEPROMStores the tokenized PBASIC program.
Interpreter ChipReads the BASIC program from the EEPROM and executes the instructions.
Serial SignalConditioningConditions voltagesignals between PC serialconnection (+/- 12V) and BASIC Stamp (5V) forProgramming.
Six Sigma – What is it? BASIC StampPin 1: SOUT
Transmits serial data during programming and using theDEBUG instruction
Pin 2: SIN
Receives serial data during programming
Pin 3: ATNUses the serial DTR line togain the Stamps attention for programming.
Pin 4: VSS
CommunicationsGround (0V).
P0P1P2P3P4P5P6P7 P8
P9P10P11P12P13P14P15
Pins 5-20:Input/Output (I/O)pins P0 through P15
Pin 21: VDD
Regulated 5V.
Pin 23: VSS
Ground (0V)
Pin 24: VIN
Un-regulated input voltage(5.5-15V)
Six Sigma – What is it?
BOE BOT Box
Six Sigma – What is it?
Board of Education Robot – BOE Bot
Six Sigma – What is it?
BOE BOT Circuit Board
Six Sigma – What is it?BOT motherboard
Off/Module Power/Servo Power
The Board of Education makes it easy to connect devices, power up and program.
Breadboard
ServoConnections
5V regulatorBattery
Wall DCSupply
Serial Programming
Port
Off/Module Power/Servo Power
Reset Switch
Power OnLight
I/O Header
Power Header
Six Sigma – What is it? Programming A program is writtenin the BASIC Stamp Editor.
The Interpreter Chip reads the program from EEPROM and executes the instructions.
The program is tokenized,or converted into symbolic format. Tokenizer
The tokenized program is transmitted through the serial cable and stored in EEPROM memory.
Six Sigma – What is it? Instructions
Six Sigma – What is it? InstructionThe FREQOUT command sends high/low signals to the
specified pin at the frequency and for the duration defined.
FREQOUT Pin, Duration, Freq1, {Freq2}
To play a note at 2000Hz which lasts 1.5 seconds:
Six Sigma – What is it? Instructions
Inner Loop
Outer Loop
The inner loop is performed fully everyrepetition of the outer loop.
Six Sigma – What is it? InstructionsWhen index = 0
Six Sigma – What is it? InstructionsWhen index = 1
Six Sigma – What is it? Instructions
Variable expressionto be checked
Conditions to checkexpression against
If condition is true,Code will be ran. If not,
it will be skipped
Each CASEwill be checked
Defines the end of theSELECT…CASE block
Six Sigma – What is it?
Shows how resources are used
• View memory
• View registers
Six Sigma – What is it?
BOE BOT Program'Robotics with the Boe-Bot - BoeBotForwardTenSeconds.BS2'Make the Boe Bot roll forward for 10 seconds
'{$STAMP BS2}'{$PBASIC 2.5}
counter VAR Word
FREQOUT 4, 2000, 3000 'create sound
FOR counter = 1 TO 407 'forward 10 seconds PULSOUT 13,850 'left wheel forward PULSOUT 12,650 'right wheel forward PAUSE 20NEXT
END
Six Sigma – What is it?
SUMO BOT Box
Six Sigma – What is it?
SUMO BOT
Six Sigma – What is it?
Sumo Bot
Six Sigma – What is it?
SUMO BOT Circuit Board
Six Sigma – What is it?
SUMO Bot 2 CPU
• Motion uses PIC16C505 processor for wheels
• Simplifies motion commands
Six Sigma – What is it?
SUMO BOT Programming
• Simpler commands because of built in functions
• Must include predefined constants
PAUSE 100
RobotData = RobotForward
GOSUB RobotSend
Six Sigma – What is it?
SUMO BOT Remote Control
Six Sigma – What is it?
Remote Control Details
Six Sigma – What is it?
Pretend it is like Sojourner
Six Sigma – What is it?
Where to go from here
Six Sigma – What is it?
Which Bot do you want• BOE BOT
– More hardware assembly– Must adjust software to hardware performance– Comes with lots of extra parts– More learning opportunities
• SUMO BOT– Quick assembly– Starts running immediately– 4 built in behaviors– Remote control – Kids like simpler requirements better