8/18/2019 Quality Tools presentation
1/125
1MTSU
Quality ToolsQuality Tools
8/18/2019 Quality Tools presentation
2/125
2MTSU
Plan
Do
Study
Act
The PDSA Cycle The PDSA Cycle
8/18/2019 Quality Tools presentation
3/125
3MTSU
The Process Improvement The Process ImprovementCycleCycle
Implement theImproved process
Select aprocess
Study/document
Seek ways toImprove it
Design anImproved process
Evaluate
Document
8/18/2019 Quality Tools presentation
4/125
4MTSU
Process ImprovementProcess Improvement
Tools Tools• There are a number of tools
that can be used for problemsolvin and processimprovement
• Tools aid in data collection andinterpretation! and provide thebasis for decision ma"in
8/18/2019 Quality Tools presentation
5/125
5MTSU
Seven #asic Quality ToolsSeven #asic Quality Tools
$% Chec" sheets&%'lo(charts)% Scatter dia rams*% +isto rams,% Pareto analysis-% Control charts.% Cause/and/e0ect dia rams
8/18/2019 Quality Tools presentation
6/125
6MTSU
Billing Errors
Wrong Account
Wrong Amount
A/R Errors
Wrong Account
Wrong Amount
onday
Chec" SheetChec" Sheet
8/18/2019 Quality Tools presentation
7/1257MTSU
'lo(chart'lo(chart
Process 1ood2 Process 1ood2 Process
Process
8/18/2019 Quality Tools presentation
8/1258MTSU
Scatter Dia ramScatter Dia ram
Variable A
Variable B
8/18/2019 Quality Tools presentation
9/1259MTSU
+isto ram+isto ram
frequency
A B C D E
8/18/2019 Quality Tools presentation
10/12510MTSU
80% of theproblemsmay beattributed to20% of thecauses.
80% of theproblemsmay beattributed to20% of thecauses.
Smearedprint
N u m
b e r o f
d e f e c t s
Off center
Missinglabel
Loose Other
Pareto AnalysisPareto Analysis
8/18/2019 Quality Tools presentation
11/12511MTSU
970
980
990
1000
1010
1020
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
UCL
LCL
Control ChartControl Chart
8/18/2019 Quality Tools presentation
12/12512MTSU
Cause/and/30ect Dia ramCause/and/30ect Dia ram
Effect
MaterialsMethods
E uipment!eople
En"ironment
#ause
#ause
#ause
#ause
#ause
#ause#ause
#ause
#ause#ause
#ause
#ause
8/18/2019 Quality Tools presentation
13/125
13MTSU
Trac"in Improvements Trac"in Improvements
!"#
#"#
#"##"#
!"#!"#
Process not centeredand not sta$le
Process centered
and sta$le
Additional improvementsmade to the process
8/18/2019 Quality Tools presentation
14/125
14MTSU
Seven Mana ement ToolsSeven Mana ement Tools
$% A4nity Dia ram&%Interrelationship Dia raph)% Tree Dia rams*% Prioriti5ation Matrices,% Matri6 Dia ram-% Process Decision Pro ram Chart.% Activity 7et(or" Dia ram
8/18/2019 Quality Tools presentation
15/125
15MTSU
Methods for 1eneratinMethods for 1eneratinIdeasIdeas
• #rainstormin• Quality circles• Intervie(in• Benchmarking
• ,8&+
8/18/2019 Quality Tools presentation
16/125
16MTSU
A #rief +istory of QualityA #rief +istory of Quality
8/18/2019 Quality Tools presentation
17/125
17MTSU
America 9e/discoversAmerica 9e/discoversDeminDemin
8/18/2019 Quality Tools presentation
18/125
18MTSU
:: and ;uranand ;uran
8/18/2019 Quality Tools presentation
19/125
19MTSU
9ediscoverin the 1urus9ediscoverin the 1urus
• Demin< 3mphasis on Statistical Control
< $* Points for Mana ement
• ;uran
< Quality Plannin and Analysis< Mana erial #rea"throu h< Quality Control +andboo"
8/18/2019 Quality Tools presentation
20/125
20MTSU
S t a t i s t i c s
8/18/2019 Quality Tools presentation
21/125
8/18/2019 Quality Tools presentation
22/125
22MTSU
8/18/2019 Quality Tools presentation
23/125
23MTSU
8/18/2019 Quality Tools presentation
24/125
24MTSU
8/18/2019 Quality Tools presentation
25/125
25MTSU
8/18/2019 Quality Tools presentation
26/125
26MTSU
8/18/2019 Quality Tools presentation
27/125
27MTSU
8/18/2019 Quality Tools presentation
28/125
28MTSU
8/18/2019 Quality Tools presentation
29/125
8/18/2019 Quality Tools presentation
30/125
30MTSU
S t a t i s t i c s
8/18/2019 Quality Tools presentation
31/125
31MTSU
8 t T C
8/18/2019 Quality Tools presentation
32/125
32MTSU
8 at Types o Compan esa ypes o ompan esCan #ene=t from Si6Can #ene=t from Si6
Si ma2Si ma2• Companies that bene=t from structuredor ani5ational improvement
• Companies that need to improve customersatisfaction
• All types of companies can bene=t>< Manufacturin
< Service< 7on/pro=t< 3ducational
8/18/2019 Quality Tools presentation
33/125
33MTSU
8hat is Si6 Si ma28hat is Si6 Si ma2
A%Customer 'ocus < 'ocus on (hatis critical to customers
#% Data Driven < 36tensive use ofstatistical tools
C%9obust Methodolo y < Tools plusimplementation methods to ma"esuccess more li"ely
8/18/2019 Quality Tools presentation
34/125
34MTSU
8hat is Si6 Si ma28hat is Si6 Si ma2Key ConceptsKey Concepts
$% Critical to Quality> 8hat attributesare most important to the
customer2 ?CTQ! CTC! CTD@&%Defect> 'ailin to deliver (hat the
customer (ants e6pects ?DPMB@
)% ariation> The level ofunpredictability the customere6periences
8/18/2019 Quality Tools presentation
35/125
35MTSU
8hat is Si6 Si ma28hat is Si6 Si ma2 Key ConceptsKey Concepts
,% Process Capability> 8hat yourprocess can deliver < consistently
-% Stable Bperations> Stable ops arepredictable
.% Desi n for Si6 Si ma> Desi ninto meet customer needs andprocess capability
8/18/2019 Quality Tools presentation
36/125
36MTSU
DMAD / DMAICDMAD / DMAIC
Define
Design
Verify
Measure
Analyze
Define
Improve
Control
Measure
Analyze
New Processes Existing Processes
8/18/2019 Quality Tools presentation
37/125
37MTSU
Statistics iteStatistics iteCenteredCentered 33 σσ ProcessProcess
LSL USL
8/18/2019 Quality Tools presentation
38/125
38MTSU
Statistics iteStatistics ite CenteredCentered 33 σσ ProcessProcess
LSL USL
8/18/2019 Quality Tools presentation
39/125
39MTSU
Statistics iteStatistics ite CenteredCentered 33 σσ ProcessProcess
LSL USL
!n"c!n#!rming$r!%uct
1&300 '$()
8/18/2019 Quality Tools presentation
40/125
40MTSU
Statistics iteStatistics ite CenteredCentered 33 σσ ProcessProcess
LSL USL
!n"c!n#!rming$r!%uct
2&600 '$()
8/18/2019 Quality Tools presentation
41/125
41MTSU
Statistics iteStatistics ite ShiftedShifted 33 σσ ProcessProcess
LSL USL
1*5 mean shi#t
8/18/2019 Quality Tools presentation
42/125
42MTSU
Statistics iteStatistics ite ShiftedShifted 33 σσ ProcessProcess
LSL USL
!n"c!n#!rming$r!%uct
66&800 '$()
1*5 mean shi#t
8/18/2019 Quality Tools presentation
43/125
43MTSU
Statistics iteStatistics ite ShiftedShifted 33 σσ ProcessProcess
Cost to your company – 15-30%of sales
LSL USL
!n"c!n#!rming$r!%uct
66&800 '$()
1*5 mean shi#t
8/18/2019 Quality Tools presentation
44/125
8/18/2019 Quality Tools presentation
45/125
45MTSU
Statistics iteStatistics ite Centered -Centered - σσ ProcessProcess
LSL USL
8/18/2019 Quality Tools presentation
46/125
46MTSU
Statistics iteStatistics ite Shifted -Shifted - σσ ProcessProcess
LSL USL
1*5 mean shi#t
8/18/2019 Quality Tools presentation
47/125
47MTSU
Statistics iteStatistics ite Shifted -Shifted - σσ ProcessProcess
LSL USL
1*5 mean shi#t
!n"c!n#!rming$r!%uct
3*4 '$()
8/18/2019 Quality Tools presentation
48/125
48MTSU
&&.&&&''% $' Sigma
• 20(000 lost articles of mail per20(000 lost articles of mail per
hourhour
• )(000 incorrect surgical)(000 incorrect surgicaloperations per *ee+ operations per *ee+
• ,*o short or long landings at,*o short or long landings at
most ma-or airports each daymost ma-or airports each day
• 200(000 *rong drug prescriptions200(000 *rong drug prescriptionseach yeareach year
• No electricity for almost se"enNo electricity for almost se"en
hours each monthhours each month
• Se"en articles lost per hourSe"en articles lost per hour
• 2 incorrect operations per *ee+2 incorrect operations per *ee+
• One short or long landing e"eryOne short or long landing e"eryfi"e yearsfi"e years
• 0 *rong prescriptions per year0 *rong prescriptions per year
• One hour *ithout electricity e"eryOne hour *ithout electricity e"ery/ years/ years
&&% $/.8 Sigma
Why Six Sigma?Why Six Sigma?
8/18/2019 Quality Tools presentation
49/125
49MTSU
Si6 Si maSi6 Si maBreakthrough Strategy Breakthrough Strategy
• De=ne• Measure• Analy5e• Improve• Control
8/18/2019 Quality Tools presentation
50/125
50MTSU
DMAD / DMAICDMAD / DMAIC
Define
Design
Verify
Measure
Analyze
Define
Improve
Control
Measure
Analyze
Existing ProcessesNew Processes
8/18/2019 Quality Tools presentation
51/125
51MTSU
De=ne / Selectin ProEectsDe=ne / Selectin ProEects
• The proEect must relate tocustomer satisfaction
• The proEectFs results must reducedefects by some threshold amount• The proEect should achieve some
threshold of cost savin s%
8/18/2019 Quality Tools presentation
52/125
52MTSU
Criteria for ProEectCriteria for ProEectSelectionSelection
• Does it involve recurrinevents2
• Is the scope narro(2• Do measures e6ist2• Do you have control of the
process2
8/18/2019 Quality Tools presentation
53/125
53MTSU
De=ne Phase! ContinuedDe=ne Phase! Continued
• If these criteria are met then>$@ Identify the customers involved! both
internal and e6ternal to the function%&@ 'ind out (hat the customerFs CTFsare ?Critical to Quality! Critical toDelivery! Critical to Cost! etc@%)@ De=ne the proEect scope and oals%*@ Map the process to be improved%
8/18/2019 Quality Tools presentation
54/125
54MTSU
De=ne Phase / ToolsDe=ne Phase / Tools
• $r!+ect Charter• Sta"eholder
Analysis• A4nity Dia ram• SIPBC
• oice of theCustomer• CT Tree
• Gano Model• S8BT Analysis
• Cause/and/30ectDia rams
• SupplierSe mentation
• ProEectMana ement
8/18/2019 Quality Tools presentation
55/125
55MTSU
CharterCharter
• Problem statement• #usiness case• 1oals! milestones!
success criteria! Hdeliverables
• ProEect scope boundaries
• 9oles H responsibilities• Sta"eholder support
approval needed
8/18/2019 Quality Tools presentation
56/125
56MTSU
De=ne PhaseDe=ne PhaseCharter Development Charter Development
Charter < An a reement bet(eenmana ement and proEect teammembers about (hat the team (illaccomplish%
h dCh P idi
8/18/2019 Quality Tools presentation
57/125
57MTSU
Charter> ProvidinCharter> ProvidinDirectionDirection
ou have to be
careful if youdonFt "no((here youFre
oin ! %%%because youmi ht not et
there%
8/18/2019 Quality Tools presentation
58/125
h
8/18/2019 Quality Tools presentation
59/125
59MTSU
De=ne PhaseDe=ne PhaseCharter – What it doesCharter – What it does
• Provides overvie( of purpose• Describes (hy you are (or"in on
this proEect ?business case@• De=nes scope of proEect• Determines deliverables• De=nes measures of success• Determines resources available
8/18/2019 Quality Tools presentation
60/125
60MTSU
#usiness Case#usiness Case
$!tential,m-r!.ement
$!tential ,m-act
Improve Juality 9educe cost! inventoryImprove BTD Shorta es ! inventory
Select better suppliers Q! K! T! reduceinventory
Implement ratinsystem
Improve supplye4ciency! bettersu liers
8/18/2019 Quality Tools presentation
61/125
61MTSU
De=ne Phase / ToolsDe=ne Phase / Tools
• ProEect Charter• Sta"eholder
Analysis• A4nity Dia ram• SIPBC•
oice of theCustomer• CT Tree
• Gano Model• S8BT Analysis
• Cause/and/30ectDia rams
• SupplierSe mentation
• ProEectMana ement
8/18/2019 Quality Tools presentation
62/125
62MTSU
SIPBC 36ampleSIPBC 36ample
/u--liers ,n-uts $r!cesses )ut-uts Cust!mers
Bps M t SupplierPerf%
/u--lier.aluati!n
Survey Bps M t
#uyers Complaints
9atinsystem
#uyers
3n r % Tech9eJts
ImprovedSupplierPerform%
3n ineerin
Mf % 9atinsystem
Commit%tosuppliers
Mf %
8/18/2019 Quality Tools presentation
63/125
8/18/2019 Quality Tools presentation
64/125
64MTSU
De=ne ButputsDe=ne Butputs
• Bnce completed! the De=ne Phaseshould ans(er the follo(in
Juestions>$@ 8ho is the customer2&@ 8hat matters2
)@ 8hat is the scope2*@ 8hat defect am I tryin to reduce2,@ 8hat are the improvement tar ets2
D PhD Ph
8/18/2019 Quality Tools presentation
65/125
65MTSU
De=ne PhaseDe=ne Phase Toll 1ate 9evie( Toll 1ate 9evie(
• Submit proEect storyboard tosponsor
• Toll 1ate revie( presentation• Sponsor provides feedbac"• ProEect corrections are made prior
to proceedin to the ne6t phase
8/18/2019 Quality Tools presentation
66/125
66MTSU
The Measure Phase The Measure Phase
• Purpose< To collect current performance of the
process identi=ed in the De=ne phase
< This data is used to determinesources of variation and serve as abenchmar" to validate improvements
8/18/2019 Quality Tools presentation
67/125
67MTSU
MeasurementsMeasurements
• #ene=ts of havin ood data needto out(ei h the costs of ettin it
• 8hat does this measure do for theProEect2
8/18/2019 Quality Tools presentation
68/125
68MTSU
The Measure Phase The Measure Phase
• Upon completion of the measure phase!ProEect Teams (ill have>
L A plan for collectin data that speci=es thetype of data needed and techniJues forcollectin the data
L A validated measurement system thatensures the accuracy and consistency ofthe data collected
L A su4cient data set for problem analysis
8/18/2019 Quality Tools presentation
69/125
69MTSU
Measure / Gey ConceptsMeasure / Gey Concepts
• Measurement• ariation
< 36ists naturally in any process and is thereason Si6 Si ma proEects are underta"en
• Data• Data Collection Plan
• Measurement System Analysis< 3nsures measurement techniJues are
reproducible and repeatable
8/18/2019 Quality Tools presentation
70/125
70MTSU
9ecordin Measurements9ecordin Measurements
• ) sta es< The output sta e
L These tell ho( (ell customer needs arebein met
< Parts of the processL These are ta"en at critical points in the
process< The input sta e
L These evaluate contributions to the processthat are turned into value for the customer
8/18/2019 Quality Tools presentation
71/125
71MTSU
9ecordin Measurements9ecordin Measurements
• Butput Sta e< Shorta es
< ine shutdo(ns< Quality < discrepant material< Material price variances
< Internal customer survey
8/18/2019 Quality Tools presentation
72/125
72MTSU
9ecordin Measurements9ecordin Measurements
• Parts of the process< ProEect milestones
< Supplier ship on time performance< Supplier BTD< Supplier internal throu hput yield
< Supplier su ested cost reductions
8/18/2019 Quality Tools presentation
73/125
73MTSU
9ecordin Measurements9ecordin Measurements
• The input sta e< Supplier base si5e
< #uyers (ith de rees< of spend covered by TCFs< of spend from reverse auction
< Supplier 'M3AFs
8/18/2019 Quality Tools presentation
74/125
74MTSU
Bperational De=nitionsBperational De=nitions
8alter She(hart! the inventorof statistical process control!
believed his (or" onoperational de=nitions to be of
reater importance than his(or" on control charts%
8/18/2019 Quality Tools presentation
75/125
75MTSU
Bperational De=nitionsBperational De=nitions
NAn !-erati!nal %e niti!n is a
procedure a reed upon fortranslation of a concept intomeasurement of some "ind%O
Bperational de=nitions should bevalid and reliable%
Demin ! $ -
8/18/2019 Quality Tools presentation
76/125
76MTSU
Bperational De=nitions2Bperational De=nitions2
Slump! I ainFt in noslump% I Eust ainFt
hittin %
8/18/2019 Quality Tools presentation
77/125
77MTSU
Bperational De=nitionsBperational De=nitions
• Bn/Time Delivery• Bn/Time Payment
• ate• Defective• Clean• 1ood communication• 3n ineerin support
Do you, your management, and yourDo you, your management, and your
suppliers agree on these definitions?suppliers agree on these definitions?
8/18/2019 Quality Tools presentation
78/125
78MTSU
Determinin Data TypeDeterminin Data Type
• 8hat do (e (ant to "no(2
• 9evie( materials developed durindesi n phase
• 8hat characteristics do (e need tolearn more about2
8/18/2019 Quality Tools presentation
79/125
79MTSU
Data Collection PlanData Collection Plan
• 8hat data (ill be collected2
• 8hy is it needed2• 8ho is responsible2• +o( (ill it be collected2• 8hen (ill it be collected2• 8here (ill it be collected2
8/18/2019 Quality Tools presentation
80/125
8/18/2019 Quality Tools presentation
81/125
81MTSU
Analy5e PhaseAnaly5e Phase
• The analy5e phase allo(s theProEect Team to tar etimprovement opportunities by
ta"in a closer loo" at the data%
8/18/2019 Quality Tools presentation
82/125
82MTSU
Analy5e PhaseAnaly5e Phase
• Capability Analysis / establishin currentperformance level
• 1raphical Analysis / a visual indicationof performance usin raphs
• 9oot Cause Analysis < developin ahypothesis about the causes of variation
• 9oot Cause eri=cation < verifyin thatthe planned action (ill enerate thedesired improvement
8/18/2019 Quality Tools presentation
83/125
83MTSU
Process CapabilityProcess Capability
8hen selectin a process toperform an operation! the inherent
variability of process output shouldbe compared to the ran e ortolerances allo(ed by thedesi nerFs speci=cations%
8/18/2019 Quality Tools presentation
84/125
84MTSU
Process CapabilityProcess Capability
#ower S peci(ication
!pper Speci(ication
A signi(icant portion o( the proce ss output(alls outside o( the speci(ication width
In other words) is theprocess capa$le o(producing the item
withinspeci(ications*
uch o( the process output(its within speci(ication width
Almost all o( the process output(its within the speci(ication width
process distribution
Analy5e PhaseAnaly5e Phase
8/18/2019 Quality Tools presentation
85/125
85MTSU
Analy5e PhaseAnaly5e Phase Cause +ypothesesCause +ypotheses
• Identifyin Bbvious Process Problems< Disconnects< #ottlenec"s< 9edundancies< Unnecessary distance< 9e(or"
< Decision points
Process Map Review
Analy5e PhaseAnaly5e Phase
8/18/2019 Quality Tools presentation
86/125
86MTSU
Analy5e PhaseAnaly5e Phase Cause +ypothesesCause +ypotheses
• Quantifyin alue/Added Steps
< alue/Addin< alue/3nablin< 7on/ alue/Addin
Process Map Review
Analy5e PhaseAnaly5e Phase
8/18/2019 Quality Tools presentation
87/125
87MTSU
Analy5e PhaseAnaly5e Phase Cause +ypothesesCause +ypotheses
• Process Time Analysis
< 8or" time ?value! but often only , @< 8ait ?H Jueue@ time ?usually dominates@< Setup time ?tremendous levera e@< Move time ?process dependent@
Analy5e PhaseAnaly5e Phase
8/18/2019 Quality Tools presentation
88/125
88MTSU
Analy5e PhaseAnaly5e Phase Tools Tools
• #rainstormin % % % And beyondR• Process Maps
• Cause/and/30ect Dia rams• 'ocused Problem Statement• Statistical Tools
8/18/2019 Quality Tools presentation
89/125
3lements of Improve3lements of Improve
8/18/2019 Quality Tools presentation
90/125
90MTSU
3lements of Improve3lements of ImprovePhasePhase
1enerate ImprovementAlternatives
Create a NShould #eO Process MapConduct 'M3APerform Cost #ene=t Analysis
Pilotalidate Improvement
8/18/2019 Quality Tools presentation
91/125
'ailure Modes 30ects'ailure Modes 30ects
8/18/2019 Quality Tools presentation
92/125
92MTSU
ailure Modes 30ectsailure Modes 30ectsAnalysisAnalysis
• Identify failure modes < !o" can this product or process #ail$
• Identify failure e0ects < Whathappens "hen this #ailure occurs$
• Identify potential causes of thee0ects H their probability of
occurrin %• 9ate the li"elihood of detectin the
occurrence%
3'M3A / B
8/18/2019 Quality Tools presentation
93/125
93MTSU
'M3A / Butput'M3A / Butput
• 9an"ed list of products thatcontribute to ris"
•ist of actions and personsresponsible for addressin the ris"
• 9evised ran"ed priority list
Improvement PhaseImprovement Phase
8/18/2019 Quality Tools presentation
94/125
94MTSU
Improvement PhaseImprovement PhaseMethodsMethods
!"#
#"#
#"##"#
!"#!"#
Process not centeredand not in control
Process centeredand in control
Evidence o( additionalimprovements
9evie( of Improvement9evie( of Improvement
8/18/2019 Quality Tools presentation
95/125
95MTSU
9evie( of Improvement9evie( of ImprovementPhasePhase
• 1enerate ImprovementAlternatives
• Create a NShould #eO Process Map• Conduct 'M3A• Perform Cost #ene=t Analysis
• Pilot• alidate Improvement
1eneratin Improvement1eneratin Improvement
8/18/2019 Quality Tools presentation
96/125
96MTSU
1eneratin Improvement1eneratin ImprovementAlternativesAlternatives
De=ne Improvement Criteria
1enerate Possible Improvements3valuate Improvements and Ma"e#est Choice
ilPil
8/18/2019 Quality Tools presentation
97/125
97MTSU
PilotPilot
#ene=ts of Pilot• Determine best (ay to implement the
improvement• o(ers ris" of failure• Increases opportunity for feedbac"• Bbtain buy/in from a0ected personnel
• Provides opportunity to revise theimprovement before fullimplementation
8/18/2019 Quality Tools presentation
98/125
98MTSU
Sta"eholder AnalysisSta"eholder Analysis
$e!-le !rr!u-s
Le.el !#
C!mmitment
#uy Mf 3n
3nthusiastic Support+elp it (or"Compliant+esitantIndi0erentUncooperative
Bpposed
9evie( of Implementation9evie( of Implementation
8/18/2019 Quality Tools presentation
99/125
99MTSU
9evie( of Implementation( pPhasePhase
• 1enerate ImprovementAlternatives
• Create a NShould #eO Process Map• Conduct 'M3A• Perform Cost #ene=t Analysis
• Pilot• alidate Improvement
Control PhaseControl Phase
8/18/2019 Quality Tools presentation
100/125
100MTSU
8hy is it important28hy is it important2
• The Control Phase be ins as theproEect team tries to eliminate
errors by “Mistake Proo ng” their improvement alternative%• Mista"e Proo=n attempts to
eliminate the opportunities forerror%
8/18/2019 Quality Tools presentation
101/125
8/18/2019 Quality Tools presentation
102/125
C t l Ph )C t l Ph )
8/18/2019 Quality Tools presentation
103/125
103MTSU
Control Phase )Control Phase )
• The Control Phase ends (hen>$@ Standard Bperatin Procedures havebeen updated%
&@ Process Bperators! the people (ho dothe Eob! have been trained for the ne(process%
• Bnce completed! the Control Phase
should sustain the ains the proEectmade (hile implementin on oinprocess controls%
C t l Ph *C t l Ph *
8/18/2019 Quality Tools presentation
104/125
104MTSU
Control Phase *Control Phase *
• 8hen is a proEect complete2$@ 8hen other #lac" #elts can see
the on oin controls (or"&@ 8hen the customer sees theresults)@ 8hen the business sees themoney%
Si6 Si maSi6 Si ma
8/18/2019 Quality Tools presentation
105/125
105MTSU
Si Sigma PeopleSi Sigma People
• 36ecutives• Champions ?deployment! proEect@
• Master #lac" #elts• #lac" #elts• 1reen #elts
Control PhaseControl Phase
8/18/2019 Quality Tools presentation
106/125
106MTSU
MethodsMethods
• Durin the Control Phase the ProEectteam (ill>$@ Develop a plan to ma"e sure themeasurement system ill remainrele!ant over the lon term%&@"sta#lis$ Control C$arts the processo(ner (ill use to mana e the process%)@ Create a Control Plan to addresssituations that mi ht cause the process tomove out of control%
Statistical Process ControlStatistical Process Control
8/18/2019 Quality Tools presentation
107/125
107MTSU
?SPC@?SPC@
• Chance variations are the many sources ofvariation (ithin a process that is in
statistical control% They behave li"e aconstant system of random chance causes%
• If only natural causes of variation arepresent! the output of a process forms adistribution that is stable over time and ispredictable%
Statistical Process ControlStatistical Process Control
8/18/2019 Quality Tools presentation
108/125
108MTSU
?SPC@?SPC@
• Assi nable variation in a process canbe traced to a speci=c reason%
Machine (ear MisadEusted eJuipment 'ati ued or untrained (or"ers
• If assi nable causes of variation are
present! the process output is notstable over time and is not predictable%
SPC / Assi nable Ca sesSPC / Assi nable Causes
8/18/2019 Quality Tools presentation
109/125
109MTSU
SPC / Assi nable CausesSPC / Assi nable Causes
The operational de=nition ofassi nable variation is variation
that causes out/of/control pointson a control chart%
7atural Patterns or ariations7atural Patterns or ariations
8/18/2019 Quality Tools presentation
110/125
110MTSU
7atural Patterns or ariations7atural Patterns or ariations
7atural patterns e6hibit the follo(in characteristics>
• Most of the points are near the centerline%• A fe( points spread out and approach the control
limits%• 7one ?or only on rare occasions@ of the points
e6ceeds the control limits%
%e#erence& Statistical Quality Control +andboo" ' Western Electric
Unnatural Patterns orUnnatural Patterns or
8/18/2019 Quality Tools presentation
111/125
111MTSU
ariationsariations
Unnatural patterns e6hibit the follo(in characteristics>
• Absence of points near the centerline produces apattern "no(n as a Nmi6ture%O
• Absence of points near the control limits produces anunnatural pattern "no(n as Nstrati=cation%O
• Presence of points outside of the control limits
produces an unnatural pattern "no(n as Ninstability%O%e#erence& Statistical Quality Control +andboo" ' Western Electric
Tests for Unnatural PatternsTests for Unnatural Patterns
8/18/2019 Quality Tools presentation
112/125
112MTSU
Tests for Unnatural Patterns Tests for Unnatural Patterns
• Instability< & single point falls outsi'e of t$e 3 sigma control
limits(< T(o out of three successive points fall in the outer one third
of the control limits%< 'our out of =ve successive points fall in the outer t(o thirds
of the control limits%< 3i ht successive points fall on one side of the centerline%
• Systematic variable< A lon series of points are hi h! lo(! hi h! lo( (ithout
interruption%%e#erence& Statistical Quality Control +andboo" ' Western Electric
Statistical Process ControlStatistical Process Control
8/18/2019 Quality Tools presentation
113/125
113MTSU
8hy use avera es28hy use avera es2
• To create a normal distribution
• Avera es are more sensitive tochan e than individuals
Central imit TheoremCentral imit Theorem
8/18/2019 Quality Tools presentation
114/125
114MTSU
SimulationSimulation
The distribution ofa sampleapproachesnormal even(hen the parentpopulation is notnormallydistributed%
Control PhaseControl Phase
8/18/2019 Quality Tools presentation
115/125
115MTSU
!"#
#"#
'+"hart
!"#
#"#
R+chart
Dri(t Detected
,o dri(t detected
process mean drifting upward
ProcessDistribution
Mean and 9an e ChartsMean and 9an e Charts
8/18/2019 Quality Tools presentation
116/125
8/18/2019 Quality Tools presentation
117/125
Control PhaseControl Phase
8/18/2019 Quality Tools presentation
118/125
118MTSU
Control PlansControl Plans
• Structured approach for desi ninvalue added control methods
• Control actions necessary toensure output Juality
• May include controls any(here in
the process
Control PhaseControl Phase
8/18/2019 Quality Tools presentation
119/125
119MTSU
9adar Chart9adar ChartProduct Features -
Data Entry Errors
Days Late
Savings by Project
8/18/2019 Quality Tools presentation
120/125
'inal Toll 1ate 9evie('inal Toll 1ate 9evie(
8/18/2019 Quality Tools presentation
121/125
121MTSU
inal Toll 1ate 9evie(inal Toll 1ate 9evie(
• Submit proEect storyboard to sponsor• Toll 1ate revie( presentation
< Did the team carry out the a reed upontas"s2
< Did the team achieve the desired results2
• Sponsor provides feedbac"
• ProEect corrections are made prior totermination or proceedin to ne6t cycle
8hy TQM 'ails8hy TQM 'ails
8/18/2019 Quality Tools presentation
122/125
122MTSU
8hy TQM ails8hy TQM ails
• ac" of Top Mana ement Commitment
• 8asted 3ducation H Trainin
• ac" of Short/Term 9esults
• 'ailure to 3mpo(er 3mployees
Brown, Hitchcock, and Willard - 1994
"ommitment!p -ront
Appropriate.raining
Bi "ase.hreshold
"harter
8hy Si6 Si ma 'ails8hy Si6 Si ma 'ails
8/18/2019 Quality Tools presentation
123/125
123MTSU
y?and it does@?and it does@
• ac" of TopMana ementCommitment
• Interdepartmental cross/functional issues
• Communication
• People
Quality ToolsQuality Tools
8/18/2019 Quality Tools presentation
124/125
124MTSU
Quality ToolsQuality Tools
im all Bullingt!n& $h*'*
9eferences
8/18/2019 Quality Tools presentation
125/125
#oo"s>• Si6 Si ma Poc"et 1uide ?9ath H Stron Fs@• The #lac" #elt Memory ;o er ?1BA QPC@• Si6 Si ma ?+arry and Schroeder@• Implementin Si6 Si ma ?#reyfo le@• The Si6 Si ma 8ay Team 'ieldboo" ?Pande! et al@• The ision of Si6 Si ma> A roadmap for brea"throu h
?+arry@• 8hy TQM 'ails and 8hat To Do About It ?#ro(n! +itchcoc"!
H 8illard@
8eb sites>• (((%isi6si ma%com• (((% e%com si6si ma
(((% J%
http://www.ge.com/sixsigmahttp://www.asq.org/http://www.ge.com/sixsigma