STM Quality
Limited
Six Sigma
TOTAL QUALITY MANAGEMENT
6s
©©ABSL
Power Solutions
STM Quality
Limited 2007
What is ‘Six Sigma’?
STM Quality
Limited
 Six Sigma is a quality measure &
improvement program developed by
Motorola.
 It is used to reduce product defects, improve
quality and increase profitability.
© STM Quality Limited
What Does Sigma Mean?
STM Quality
Limited
 Sigma is a Greek letter s and is used in
statistics to denote variation, or ‘standard
deviation’.
 To control a process to the point of six sigma
means to control defects to 3.4 per million
items.
© STM Quality Limited
The Use Of Six Sigma
STM Quality
Limited
 By identifying factors which are critical to
quality, we can:
 Reduce process variation;
 Improve capabilities;
 Increase stability;
 Work towards ZERO DEFECTS.
© STM Quality Limited
Zero Defects
STM Quality
Limited
 If we can measure how many defects we
have in any given process, then we can
systematically work towards eliminating them
and get as close as possible to zero defects.
© STM Quality Limited
Key Elements of Quality
STM Quality
Limited
1. The Customer.
2. The Process.
3. The Employee.
© STM Quality Limited
1. The Customer
STM Quality
Limited
 Defines quality;
 Expects performance, reliability, competitive
price, on time delivery, service, correct
transaction processes, etc.
 Being good is not enough – customers need
to be delighted!
© STM Quality Limited
2. The Process
STM Quality
Limited
 There is a need for us to look at our business
from the customer’s perspective.
 That is, to look at our processes from the
outside in.
© STM Quality Limited
3. The Employee
STM Quality
Limited
 Lets put it simply:
PEOPLE CREATE RESULTS!
© STM Quality Limited
The DMAIC Model
STM Quality
Limited
 At the heart of Six Sigma is a systematic
method for analyzing & improving business
process, called DMAIC.
 The DMAIC model includes five phases.
© STM Quality Limited
Five DMAIC Phases
STM Quality
Limited
Define opportunities;
Measure performance;
Analyse opportunity;
Improve performance;
Control performance.
© STM Quality Limited
DMAIC Phases - Define
STM Quality
Limited
 Measure performance
 Various tools can be used once we have a
measurement plan.
 Benchmarking, S.P.C., calculation of process
sigma, R & R studies, etc.
© STM Quality Limited
DMAIC Phases - Measure
STM Quality
Limited
 Define opportunities
 This is the step we take to find exactly what
the requirement, measure, or concern is.
 Without defining, we cannot perform the
other elements!
© STM Quality Limited
DMAIC Phases - Analyse
STM Quality
Limited
 Analyse
 Once we have measured data we can
analyse it using cause & effect analysis;
financial assessment, value added analysis
etc.
© STM Quality Limited
DMAIC Phases - Improve
STM Quality
Limited
 Improve
 Having analysed our data we can take steps
to improve the process using Design of
Experiments, F.M.E.A., Poka-Yoke, etc.
© STM Quality Limited
DMAIC Phases - Control
STM Quality
Limited
 Control
 Once we have made process improvements
we need to control the process using Kaizan,
Control charts, 5c etc.
© STM Quality Limited
The DMAIC Process - Example
STM Quality
Limited
 Lets look at an example:
 A company is having parts failing inspection
after machining.
 Lets see how the DMAIC process could be
used…
© STM Quality Limited
The DMAIC Process –
Example: Define
STM Quality
Limited
 Define:
 Inspection are rejecting high number of
parts after final machining.
© STM Quality Limited
The DMAIC Process –
Example: Measure
STM Quality
Limited
 Measure:
 Yield obtained;
 Number of defects in total measured so
that standard deviation can be defined.
© STM Quality Limited
The DMAIC Process –
Example: Analyse
STM Quality
Limited
 Analyse:
 Operators;
 Material;
 Identified variables that could impact
production;
 Different experiments conducted;
 Range of acceptable levels determined.
© STM Quality Limited
The DMAIC Process –
Example: Improve
STM Quality
Limited
 Improve:
 Operating instructions changed;
 Production levels bought into line with
capacity;
 Final production yield increased!
© STM Quality Limited
The DMAIC Process –
Example: Control
STM Quality
Limited
 Control:
 Control charts introduced for each
machine;
 Corrective Action Plan provided for
defects.
© STM Quality Limited
Six Sigma
STM Quality
Limited
 So as can be seen from the example, the
DMAIC process was applied.
 Remember that there may not be a ‘quick fix’
and that resources need to be applied to a
problem.
© STM Quality Limited
Six Sigma Belts
STM Quality
Limited
 Experts at Six Sigma disciplines are often
referred to as ‘Master Black Belts’.
 These experts often train others in the
disciplines, being ‘Black Belts’ and ‘Green
Belts’.
© STM Quality Limited