materi vii.pdf
TRANSCRIPT
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Six-Sigma Management and Tools
TKI 212 - Pengendalian Kualitas
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Six-Sigma Management and Tools
What is Six-Sigma? Organizing Six-Sigma
DMAIC overview
DMAIC phases
Design for Six-Sigma
Using Six-Sigma from a contingency perspective
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Six-Sigma Management and ToolsWhat is Six-Sigma?
Sigma ( ) is a greek letter used to designate astandard deviation (SD) in statistics
Six refers to the number of SDs from the specialized
limit to the mean
Six-Sigma: about 0.5% of products will not meetspecification
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Six-Sigma Management and ToolsWhat is Six-Sigma?
Sigma Level Long-term ppm* defects
1 691,462
2 308,5383 66 807
4 6,210
5 233
6 3.4
* ppm = Parts Per Million
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Six-Sigma Management and ToolsWhat is Six-Sigma?
Six-Sigma is designed to handle the most difficultquality problems
% Quality Problems Techniques
90% Basic tools of Quality
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Six-Sigma Management and ToolsOrganizing Six-Sigma
The key players Champion. Work with black belts to identify possible
projects
Master Black Belts. Work with and train new black
belts
Black Belts. Committed full time to completing cost-
reduction projects
Green Belts. Trained in basic quality tools
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Six-Sigma Management and ToolsOrganizing Six-Sigma
In a company with 100 employees there might be: One black belt
Sixty green belts
Some companies have yellow belts, employees
familiar with im rovement rocesses
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Six-Sigma Management and ToolsDMAIC overview
Stands for: Define
Measure
Analyze
Control
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Six-Sigma Management and ToolsDMAIC phases
DefineFour Phases:
1. Develop the business case
2. Project evaluation
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4. Project definition
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Six-Sigma Management and ToolsDMAIC phases
Define Developing the Business Case:
1. Identify a group of possible projects
2. Writing the business case
3. Stratif in the business case into roblem
statement and objective statement
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Six-Sigma Management and ToolsDMAIC phases
DefineRUMBA is used to check the efficacy of the business
case
1. Realistic
2. Understandable
3. Measurable
4. Believable
5. Actionable
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Six-Sigma Management and ToolsDMAIC phases
MeasureTwo major steps:
1. Select process outcomes
2. Verifying measurements
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Six-Sigma Management and ToolsDMAIC phases
MeasureTwo major steps:
1. Select process outcomes
Tools Used:
XY matrix
FMEA
Gauge R&R
Capability Assessment
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Six-Sigma Management and ToolsDMAIC phases
MeasureTwo major steps:
1. Select process outcomes
2. Verifying measurements
Use gauges, calipers and other tools
Management System Analysis (MSA) is used to
determine if measurements are consistent
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Six-Sigma Management and ToolsDMAIC phases
MeasureTwo major steps:
2. Verifying measurements
Gauge R&R
Determine the accuracy and precision of your
measurements
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Six-Sigma Management and ToolsDMAIC phases
AnalyzeThree major steps:
1. Define your performance objectives (Xs)
2. Identify independent variables
.
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Six-Sigma Management and ToolsDMAIC phases
AnalyzeThree major steps:
1. Define your performance objectives (Xs)
Identify the independent variables where data
will be athered
Process maps, XY matrices brainstorming and
FMEAs are the tools used
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Six-Sigma Management and ToolsDMAIC phases
AnalyzeThree major steps:
3. Analyze sources of variability
Use visual and statistical tools to better understand
the relationshi s between de endent and
independent variables
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Six-Sigma Management and ToolsDMAIC phases
Improve Off-line experimentation
ANOVA
Taguchi
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Six-Sigma Management and ToolsDMAIC phases
ControlManage the improved processes using control charts
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Six-Sigma Management and ToolsThe Taguchi method
Design of Experiment (DOE) Robust design - designed so that they are inherently
defect free
Concept Design
Parameter Design
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Six-Sigma Management and ToolsThe Taguchi method
The Taguchi Method provides:1. A basis for determining the functional relationship
between controllable factors
2. A procedure for examining the relationship between
random noise and product or service variability
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Six-Sigma Management and ToolsThe Taguchi method
Design of Experiment (DOE) Robust design - designed so that they are inherently
defect free
Concept Design - examining competing technologies
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Six-Sigma Management and ToolsThe Taguchi method
The Taguchi Process1. Problem identification
2. Brainstorming session
3. Experimental design
4. Experimentation5. Analysis
6. Confirming experiment
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Six-Sigma Management and ToolsDesign for Six-Sigma
Used in designing new products with highperformance
Instead of DMAIC
1. DMADV
2. IDOV
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Six-Sigma Management and ToolsDesign for Six-Sigma
Used in designing new products with highperformance
DMADV
1. Design
2. Measure3. Analyze
4. Design
5. Verify
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Six-Sigma Management and ToolsDesign for Six-Sigma
Used in designing new products with highperformance
IDOV
1. Identify
2. Design.
4. Verity
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Six-Sigma Management and ToolsFailure Six-Sigma from a Contingency Perspective
Reasons for Six-Sigma failure:1. Lack of leadership by champions
2. Misunderstood roles and responsibility
3. Lack of appropriate culture for improvement
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Six-Sigma Management and ToolsFailure Six-Sigma from a Contingency Perspective
Reasons for Six-Sigma failure:1. Lack of leadership by champions
2. Misunderstood roles and responsibility
3. Lack of appropriate culture for improvement
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5. Faulty strategies for deployment
6. Lack of data
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Six-Sigma Management and ToolsSummary
The process for Six-Sigma is define, measure,analyze, improve and control
Keys to Six-Sigma success are skilled management,
leadership and long-term commitment