Prepared by: MOHAMAD SHARIF B ISHAK B050810346

1. Prepared by: MOHAMAD SHARIF B ISHAK B050810346 MOHD KHAIRUL SHAHRIL B MUSTAQ AHMAD B050810085 KHAIRUN NAZIHAH BT KHALID B050810081 FARIZA FUZIANA BT YACOB B050810220

2. Outline • What is Six Sigma • History of Six Sigma • Definition of Six Sigma • Key focus of Six Sigma • Statistical meaning of Six Sigma • DMAIC:  Define phase  Measure phase  Analyze phase  Improve phase  Control phase 7) Benefit of applying Six Sigma 8) Challenges in implementing Six Sigma 9) Case study

3. What is Six Sigma • Six Sigma was develop by Motorola around 1985 and make famous by GE. “Six Sigma is a commited management approach to quantifiably solve problems and optimize critical process”...ASQ “implementing six sigma into your corporate cluture improves processes, maximize business performance and adds to your bottom line”...ASQ “six sigma is a discilpined and data-driven approach for problem solving in any process.” “a quality measure and improvement program developed by motorola that focuses on the control of a process to the point of 3.4 defects per million oppurtunity...”

4. What is Six Sigma “sigma” Is a measurement scale upon which improvements can be gauged. “six sigma” Is an overall methodology that drives business improvement.

5. History of Six Sigma Design for Six Sigma (DFSS)/ Six Sigma for Production Development (SSPD) Six Sigma/ Quality Awards Total Quality Control Motorola’s Six Sigma Methodology 1950s 1960s 1970 1980s 1990s 2000 2005 Statistical Quality Control ISO 9000/ Total Quality Management Lean Manufacturing Lean Six Sigma

6. Definition of Six Sigma • There are three different levels that Six Sigma can be defined and understood.

7. Key focus of six sigma • Every human activity has variability. • Every process has variability. • Variation means that a process does not produce consistent, predictable results over time. • Variation leads to defects, and defects lead to unhappy customers. • Minimizing variation is a key focus of six sigma. Variation is devil.

8. Statistical Meaning of Six Sigma Table 1: Six Sigma Process Capability, percentage of accuracy and competitive level (Schroeder,2008)

9. Purposes • Define the project’s purpose and scope and get background on the process and customer Output • A clear statement of the intended improvement and how it is to be measured • A list of what is important to customer Define Phase

10. Applicable Method and Tools

11. SIPOC • A SIPOC diagram is a tool that is used to gather a view of process information. • SIPOC stands for Suppliers, Inputs, Process, Outputsand Customers. • Benefits: • Remove ambiguity. • Immediate understanding of project boundaries. • Simple to understand by team.

12. Project Charter • A project charter is a statement of the scope, objectives and participants in a project. • Also known as a “Terms of References” or “Project Definition Report” • Benefits • Improved project management process • Help define and achieve business objectives • Create project monitoring and control.

13. VOC • VOC stands for Voice of the Customers. • Customers - Any person or organization that receives a product or service (output) from the work activities (Process) • Types of “customers”: • External (individuals or organization) • Internal (colleagues – marketing, management, stockholders) • Regulatory ( government agency – OSHA, EPA) • Benefits – improve customer loyalty, ensure continuous business growth, improve product innovation.

14. Purposes • To understand the process and its performance Output • Baseline data on current process performance • A more focused problem statement Measure Phase

15. Applicable Statistical Method and Tools • Data collection ( What, How, Who, When, Where) • Sampling • Measurement System Analysis - Gage R&R (repeatability and reproducibility) • Variation (mode, mean, median, standard deviation & variance) • Process capability (voice of process-control limits, voice of customer – specification limits)

16. Applicable Statistical Method and Tools F M E A

17. Applicable Statistical Method and Tools Ishikawa Diagram

18. Statistical Process Control (SPC)

19. Pareto Analysis

20. Analyze Phase Purpose The third stage analyze serves as an outcome of the measure stage. This stage will begin streamlining its focus on a distinct group of project issues and opportunities. In other words, this stage allows the team to further target improvement opportunities by taking a closer look at the data. Outcome/Output The team should have a strong understanding of the factors impacting their project including: Key process input variables ( the vital few Xs that impact the Y) Sources of variation where the greatest degree of variation exists.

22. Applicable Statistical Method and Tools • Tests for normality (Descriptive Statistics, Histograms): Correlation/Regression Analysis: • Analysis of Variances (ANOVA): • FMEA (Failure Mode and Effect Analysis): • Hypothesis testing methods:. • Cause & Effect Matrix: • Design of Experiments (DOE) • Control Chart • Quality Function Deployment (QFD)

23. Improvement Phase • Purpose The fourth stage improves aims to generate idea, design, and pilot and implement improvement and validate the improvement. • Outcome/Output The most important items in this stage are • the process of brainstorming, • the development of the process map, • review of the current FMEA, preliminary cost/benefit analysis, • a pilot of the recommended action and the preliminary implementation process.

24. The following steps should be taken at this stage: • Generate improvement alternatives. The emphasis here is to generate alternatives to be tested as product or process improvement. • The basic tools to be used here are brainstorming and DOE. • The process of basic tools:

25. Applicable Statistical Method and Tools

26. Purposes • To ensure the improvement can be sustained • Communicate changes to relevant people • Keep monitoring output performance • to institutionalize process or product improvement and monitor on going performance Output • understand performance expectation • what corrective actions should be executed if measurements drop below desired and anticipated levels Control Phase

27. Applicable Statistical Method and Tools

28. Operating Flow Chart(s) with Control Points • Statistical Process Control (SPC) charts

29. Control Plan Check Sheet

30. In order to implement control effective there are several factors must be identified and addressed.

31. Documentation

33. Type of visual control 5S shadow board Dashbord Takt board Control chart

34. Visual control tips

35. Benefit of Applying Six Sigma

36. Challenges in Implementing Six Sigma

37. Case Study: Summary application in Motorola

39. Conclusion • Six Sigma is a methodology that can improve the business performance and reduce the process variation. • Three different levels that Six Sigma can be defined and understood are: Metric, Methodology and Philosophy •  Methodology DMAIC is used.