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Six Sigma – What is it? Six Sigma What is it? Robert Fruit SSBB CQE

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Page 1: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

Six Sigma

What is it?

Robert Fruit SSBB CQE

Page 2: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

Page I – 2 Guaranteed Success

Page 3: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

Page I – 2 Define the Problem

Page 4: Six Sigma Lesson (Powerpoint)

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

Page 5: Six Sigma Lesson (Powerpoint)

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

Page 6: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

DMAIC • Define

• Measure

• Analyze

• Improve

• Control

Page 7: Six Sigma Lesson (Powerpoint)

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

Page 8: Six Sigma Lesson (Powerpoint)

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

Page 9: Six Sigma Lesson (Powerpoint)

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

Page 10: Six Sigma Lesson (Powerpoint)

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

Page 11: Six Sigma Lesson (Powerpoint)

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

Page 12: Six Sigma Lesson (Powerpoint)

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

Page 13: Six Sigma Lesson (Powerpoint)

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

Page 14: Six Sigma Lesson (Powerpoint)

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

Page 15: Six Sigma Lesson (Powerpoint)

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

Page 16: Six Sigma Lesson (Powerpoint)

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

Page 17: Six Sigma Lesson (Powerpoint)

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

Page 18: Six Sigma Lesson (Powerpoint)

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

Page 19: Six Sigma Lesson (Powerpoint)

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%

Page 20: Six Sigma Lesson (Powerpoint)

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

Page 21: Six Sigma Lesson (Powerpoint)

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

Page 22: Six Sigma Lesson (Powerpoint)

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

Page 23: Six Sigma Lesson (Powerpoint)

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

Page 24: Six Sigma Lesson (Powerpoint)

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

Page 25: Six Sigma Lesson (Powerpoint)

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

Page 26: Six Sigma Lesson (Powerpoint)

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

Page 27: Six Sigma Lesson (Powerpoint)

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

Page 28: Six Sigma Lesson (Powerpoint)

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

Page 29: Six Sigma Lesson (Powerpoint)

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

Page 30: Six Sigma Lesson (Powerpoint)

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

Page 31: Six Sigma Lesson (Powerpoint)

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

Page 32: Six Sigma Lesson (Powerpoint)

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%

Page 33: Six Sigma Lesson (Powerpoint)

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%

Page 34: Six Sigma Lesson (Powerpoint)

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

Page 35: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

Some Keywords

• DMAIC

• Voice of the Customer

• KIPV

• KOPV

• DPMO

Page 36: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

High Definition Television

Page 37: Six Sigma Lesson (Powerpoint)

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

Page 38: Six Sigma Lesson (Powerpoint)

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

Page 39: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

ATI HDTV Card

Page 40: Six Sigma Lesson (Powerpoint)

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

Page 41: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

ATI RADEON 9250 PCI

Page 42: Six Sigma Lesson (Powerpoint)

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

Page 43: Six Sigma Lesson (Powerpoint)

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

Page 44: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

2 Robots

Page 45: Six Sigma Lesson (Powerpoint)

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.

Page 46: Six Sigma Lesson (Powerpoint)

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)

Page 47: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

BOE BOT Box

Page 48: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

Board of Education Robot – BOE Bot

Page 49: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

BOE BOT Circuit Board

Page 50: Six Sigma Lesson (Powerpoint)

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

Page 51: Six Sigma Lesson (Powerpoint)

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.

Page 52: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it? Instructions

Page 53: Six Sigma Lesson (Powerpoint)

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:

Page 54: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it? Instructions

Inner Loop

Outer Loop

The inner loop is performed fully everyrepetition of the outer loop.

Page 55: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it? InstructionsWhen index = 0

Page 56: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it? InstructionsWhen index = 1

Page 57: Six Sigma Lesson (Powerpoint)

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

Page 58: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

Shows how resources are used

• View memory

• View registers

Page 59: Six Sigma Lesson (Powerpoint)

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

Page 60: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

SUMO BOT Box

Page 61: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

SUMO BOT

Page 62: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

Sumo Bot

Page 63: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

SUMO BOT Circuit Board

Page 64: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

SUMO Bot 2 CPU

• Motion uses PIC16C505 processor for wheels

• Simplifies motion commands

Page 65: Six Sigma Lesson (Powerpoint)

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

Page 66: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

SUMO BOT Remote Control

Page 67: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

Remote Control Details

Page 68: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

Pretend it is like Sojourner

Page 69: Six Sigma Lesson (Powerpoint)

Six Sigma – What is it?

Where to go from here

Page 70: Six Sigma Lesson (Powerpoint)

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