Application of Six Sigma Methodology

to reduce Process Variation

Plenary Lecture @

The 3rd International Conference on

Basic Sciences, Faculty of Science,

Omar Al-Mukhtar University, Libya [

3rd October’2018

Presented By

Mr. Makkena Suresh

Asst. Professor , Faculty of Engg.

Omar Al-Mukhtar Univ, Libya 26-Oct-21

Objective

To present the Six Sigma Quality Improvement

methodology in simple and usable way

26-Oct-21

Presentation Outline

1. Part 1

Overview of Six Sigma Quality

2. Part 2

Six Sigma Methodology - DMAIC

3. Part 3

Quality Costs & Benefits

Suitability of Six Sigma to Libya

26-Oct-21

PART 1:

OVERVIEW OF SIX SIGMA

26-Oct-21

What is ?

means Standard Deviation

Hence means Six Standard Deviations

Standard Deviation is the Variation (Deviation) from

the Mean (Average) value of a process

Six Sigma helps to reduce the variation in the

process.

26-Oct-21

26-Oct-21 Academic Editing Proofreading Service

Variation in Heights of People

26-Oct-21

Can we control this Variation ? No

Variation in Students Grades

26-Oct-21

Can we control this Variation ? Yes

Management Reaction to Variation

J F M A M J J A S O N D J F M A M J J A S O

What

happened???!!! What

happened???!!!

Good Job!!

Good Job!!Good Job!!

Why do we need Six Sigma ?

To Improve Quality to World-Class Levels

What is Quality ?

Why should we improve the quality ?

Global Competition , Ex. Nokia , Kodak

26-Oct-21

What is World-Class Quality Level ?

It is 99.99966 % Success Rate

In other words, it is 3.4 defects out of a million

opportunities. Six Sigma helps to reach this

level

26-Oct-21

3 Sigma quality Level – 99.7 % Success Rate

26-Oct-21

Why 6 Sigma ? Is 3 Sigma not enough ?

3 Sigma means, 99.7 % Quality Level.

According to a survey in the U.S.A , 99 % quality means:

22,000 wrong cheque transactions per hour

12 newborns will be given to the wrong parents each

day

Two unsafe planes landing at Chicago airport every

day

One hour of unsafe drinking water everyday

The list continues …..

26-Oct-21

Defects at each Sigma Level

26-Oct-21 Academic Editing Proofreading Service

PART 2:

Six Sigma Methodology - DMAIC

26-Oct-21

Six Sigma Methodology - DMAIC

26-Oct-21 Academic Editing Proofreading Service

Define Phase :What is the Problem ?

26-Oct-21

Ex - Decrease defect rate to 1 %

Use Six Sigma Tools such as

Voice of Customer

Value stream Mapping

Process Map to find variables

Process thinking map

Fish Bone Diagram to list all

variables

26-Oct-21

26-Oct-21 Academic Editing Proofreading Service

Measure Phase : Collect Data

Quantify the problem

Collect related data

Calculate Present Sigma level ,

process capability indices

26-Oct-21

6σ

LSLUSL

widthprocess

ion widthspecificatCp

3σ

LSLμ,

3σ

μUSLminCpk

26-Oct-21 Academic Editing Proofreading Service

26-Oct-21

Analyze Phase : Find the Root Cause

26-Oct-21

Compare present Cp and Cpk with Six

Sigma standards (Cp or Cpk = 2)

Use - Fish Bone diagram to find root

causes

Identify the key variable . Establish

standards

Improve Phase : Reach Excellence

26-Oct-21

Check the progress

Calculate new Cp and Cpk

Compare old and new capabilities

Improve the process

The goal is Cp , Cpk value of 2

Control Phase : Sustain the Gains

26-Oct-21

Never allow workers to change

settings

Sustain Excellence – Check Progress

26-Oct-21

PART 3: Quality Costs & Benefits

Six Sigma Suitability to Libya

Conclusions

26-Oct-21

Quality Costs - Nasa challenger disaster (1986)

– 8 dead and over a Billion dollar loss

26-Oct-21

The cause of accident was

A faulty O’ring Sealing, a kind of

Washer used to prevent escape of

Hot gasses from the engine.

It failed to expand under cold

weather.

http://www.spacesafetymagazine.com/space-disasters/challenger-disaster/challenger-management-failure/

Quality Costs - Toyota takes $2bn hit from

global safety recall (2010)

Carmaker Toyota had

brake problems with

Prius

Toyota suffered $2bn

(£1.26bn) extra costs

as a result of a global

safety recall

26-Oct-21

Source:

https://www.theguardian.com/business/2010/feb/04/toyota-safety-recall-profits

Benefits of Six Sigma

U.S. Army

Using Six Sigma methods, saved over $2 billion.

General Electric

Reduced costs in excess of $1.8 billion.

Allied Signal

Saved $800 million by implementing Six Sigma

Lift Truck Manufacturer

Saves $1.5 Million Since Adopting Six Sigma

Source: http://www.sixsigmadaily.com/saving-start-lean-six-sigma/

26-Oct-21

Is Six Sigma Suitable to Libya ?

Yes, It is certainly suitable

My own research conducted at Animal Feed plant

located in Shahaat indicated that, Libyan Industries

are suitable for the implementation of Six sigma.

Click Here to access the Research Paper

26-Oct-21

26-Oct-21

Conclusions:

Six Sigma Quality Improvement process can

be applied to any Organization.

It is possible to implement Six Sigma in

Libya , as there is a huge scope for

improvement here.

Six Sigma helps organizations to reach

World-Class Quality Levels.

26-Oct-21 Academic Editing Proofreading Service

References

26-Oct-21

26-Oct-21 Academic Editing Proofreading Service

Backup slides

26-Oct-21

26-Oct-21

26-Oct-21

W

26-Oct-21 Academic Editing Proofreading Service

How to start Six Sigma journey ?

Immediately , after

getting short training

There are various levels

of Six Sigma

certification - Yellow,

Green, Black and Red

Belts

26-Oct-21 Academic Editing Proofreading Service

26-Oct-21 Academic Editing Proofreading Service

Who offers Six Sigma Certification ?

American Society for Quality

Institute of Industrial Engineers

Chartered Quality Institut

26-Oct-21 Academic Editing Proofreading Service

How much does it Cost for Six

Sigma certification ? The cost for the IASSC Certified Black Belt

Exam is $395 USD.

The cost for the IASSC Certified Green Belt

Exam is $295 USD.

The cost for the IASSC Certified Yellow Belt

Exam is $195 USD.

26-Oct-21 Academic Editing Proofreading Service

How long will it take to see the benefits

of Six Sigma ?

3 months to 5 years depending upon the

scale of the project.

26-Oct-21 Academic Editing Proofreading Service

26-Oct-21

Universities offering 6 Sigma certificate

programs

26-Oct-21 Academic Editing Proofreading Service

University certification programs[edit]

Arizona State University[1]

Binghamton University, State University of New York[2]

Brigham Young University[3]

Brigham Young University - Hawaii[4]

Boston University[5]

California State University, Fullerton[6]

Case Western Reserve University[7]

Cleveland State University[8]

Cornell University [9]

Dartmouth College[10]

Emory University[11]

Franklin University[12]

George Washington University[13]

Georgia Institute of Technology[14]

Louisiana Tech University[22]

North Carolina State University[

26-Oct-21 Academic Editing Proofreading Service

26-Oct-21 Academic Editing Proofreading Service