PART 1/2

Facilitator

LEAN SIX SIGMA

INTRODUCTION

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Outline
Agenda
• Introduction to Six Sigma
• Six Sigma History and Application
• Basic Six Sigma Concept
• Lean Concept
• Lean Six Sigma-DMAIC
• Process Improvement & Quality Method
• Lean Six Sigma tools

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 WHAT IS SIX SIGMA?

Suatu metodologi untuk membantu organisasi

meningkatkan kapabilitasnya business
processnya. Meningkatkan performancenya,
menurunkan variasi, mengurangi defect,
improve profit, moral karyawan, quality
produk atau jasa.

https://asq.org/quality-
resources/six-sigma

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 WHAT IS SIX SIGMA?

Sigma adalah huruf Yunani yang

mewakili satuan statistik pengukuran yang
menentukan standar deviasi suatu
populasi. Ini mengukur variabilitas atau
penyebaran data.

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 WHAT IS SIX SIGMA?

❖ Six Sigma dapat digunakan sebagai ukuran

kualitas.

❖ Tingkat Kualitas Six Sigma menunjukkan

berapa banyak data yang masuk dalam persyaratan
pelanggan.

❖ Tingkat Kualitas Sigma yang lebih tinggi berarti lebih

banyak output proses, produk dan layanan, memenuhi
persyaratan pelanggan - lebih sedikit cacat (defect).
Tingkat Kualitas 6 Sigma adalah kinerja yang hampir
sempurna.

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 SEJARAH SIX SIGMA

1984 Present
1995 1997

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 Where Did Six Sigma Come From?

Started at Motorola Corporation in the mid-1980’s,

when the company discovered that products with a high first-
pass yield (i.e., those that made it through the production
process defect-free) rarely failed in actual use, resulting in
higher customer satisfaction.

Popularized by former General Electric CEO Jack

Welch’s commitment to achieving Six Sigma capability
(realized $12 Billion savings over 5 years). "Six Sigma is a
quality program that improves your customers' experience,
lowers your costs and builds better leaders."

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 Six Sigma Level
MEAN

6 Sigma
Min.Distance

Six Sigma memiliki setidaknya 6 Standard deviasi antara Mean

dan Spec Limit terdekat
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 Lean Six Sigma Application

Meskipun awal mulanya Lean Six Sigma diaplikasikan di industri manufaktur, namun
bisa diaplikasikan ke berbagai jenis industri.
9
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 SIX SIGMA GOALS

01 Reduce defects

02 Reduce variability

03 Improve yield

04 Improve customer
satisfaction

12

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 Six Sigma Concept

Every Human Activity Has Variability...

Customer
Specification
Customer
Specification

defects
Target

Reducing Variability is the Key to Understanding Six Sigma

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 Six Sigma Concept
Parking Your Car in the Garage
Has Variability...

Customer Customer
Specification Target Specification

defects defects

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 Six Sigma Concept

Sigma (σ) is a statistical concept that represents how much variation

there is in a process relative to customer specifications.
Sigma Value is based on “defects per million opportunities” (DPMO).

Six Sigma (6σ) is equivalent to 3.4 DPMO. The variation in the process is so
small that the resulting products and services are 99.99966% defect free.

Amount of Variation Effect Sigma Value

Too much Hard to produce output within Low (0 – 2)
customer specifications
Moderate Most output meets customer Middle (3 – 5)
specifications
Very little Virtually all output meets High (6)
customer specifications

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 Six Sigma Concept

Tingkat mutu dimana hanya

terdapat 3.4 defect dari
sejuta peluang (3.4 defect
per million opportunities/DPMO)

DPMO : Defect per Million Opportunity

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 Six Sigma as a Metric (Statistical)

Sigma =  = Deviation
( Square root of variance )

2
=  ( xi − x )
n −1

•Mean
•Variance
Six Sigma = data driven process improvement method
•Standard Deviation
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 What is the Mean?

In statistics the mean of a set of numbers is

the average value of those numbers. Find
the average or mean by adding up all the
numbers and dividing by how many
numbers are in the set.

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 What Is Variance?

Variance (σ2)
• In statistics is a measure of
dispersion of data points from the
mean. Population
Variance
• Low variance indicates that data
points are generally similar and do
not vary widely from the mean.
• High variance indicates that data Sample

values have greater variability and Variance

are more widely dispersed from

the mean.

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 3 Category of Variation
B
C
A
D

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 Source of Variation
Source of Variation

❑ Method
❑ Different working method
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 What Is Standard Deviation?

Standard deviation is a statistical

measure of diversity or variability in a
data set. A low standard deviation
indicates that data points are generally
close to the mean or the average
value. A high standard deviation
indicates greater variability in data
points, or higher dispersion from the
mean.

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 Reducing Variability
A 3 process because 3 standard deviations
fit between target and spec
Before
Target Customer
3 Specification

1

2

3
After

Target
6 ! Customer
Specification

By reducing the variability,

we improve the process 1 No Defects!
3

6

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 Six Sigma : Process Improvement
1s

2s

3s

(Distribution Shifted ± 1.5s)

4s
s DPMO
s PPM
1 691462
5s 2 308537
3 66807
4 6210
5 233
6 3.4
6s
Defects per Million
LSL USL Opportunities

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 What’s Wrong With 99% Quality?

3.8 Sigma Six Sigma

99% Good 99.99966% Good
20,000 articles of mail lost per hour 7 articles of mail lost per hour

Unsafe drinking water for almost 15 Unsafe drinking water for 1 minute
minutes each day every 7 months

5,000 incorrect surgical operations 1.7 incorrect surgical operations

per week per week

2 short or long landings at most major 1 short or long landing at most

airports each day major airports every 5 years

200,000 wrong drug prescriptions 68 wrong drug prescriptions

dispensed each year dispensed each year
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 Six Sigma as a Method

Y = F (X)
To get results, should we focus our behavior on the Y or X

•Y •X1…Xn
•Dependent •Independent
•Output •Input-Process
•Effect •Cause
•Monitor •Control
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 Focus: The End User
Customer: Internal or External
Consumer: The End User

the “Voice of the Consumer” (VOC)

must be translated into

the “Performance Requirement”

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 What Is Quality

• Fitness for Use (J. M. Juran)

• Conformance to Customer Requirements (P. Crosby)

• Meeting Customer Expectations (A. V. Feigenbaum)

• Customer Satisfaction (K. Ishikawa)

Define by
Quality …………..Customer !!

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 VOICE OF CUSTOMER (VOC)

“VOICE OF THE CUSTOMER” (VoC)

• Adalah ekspresi mengenai apa yang
dibutuhkan dan diinginkan oleh Customer
sebagaimana yang diucapkan/dinyatakan
secara verbal oleh Customer

• VoC dapat dibandingkan dengan data internal

(“Voice of the Process”) untuk mengetahui
performance atau kemampuan proses saat
ini
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 Critical To Quality (CTQ)

Critical To Quality (CTQ)

• adalah critical requirement tentang customer need atau
• persyaratan produk/service yang penting (critical) yang
diinginkan pelanggan

Contoh :
Proses / Produk CTQ
Kemeja jahitan rapi, ukuran sesuai, bahan sesuai
Pengiriman barang tepat waktu, tepat jumlah, tepat spek

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 Konversi CT Quality (CTQ) To CT Process

CTQ

CT PRODUCT

CT PROCESS

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CALCULATING SIGMA LEVEL & DPMO
 DPMO FORMULA

Total Opportunity= Sample Size X Defect

Opportunity)

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 DPMO EXAMPLE : NAIL PRODUCTION
Sample
Defect Opportunity
Size

Sample Size Total=19

Sample size (U) = 10
No. of Defect (D) = 19
Defect Opportunity = 5

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 SUMMARY DATA

Number of Defect (D) = 19 total defects

Sample Size (U) = 10 nails

Number of Defect Opportunity (O) = 5 opportunities

(categories of defect types)

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 DPMO CALCULATION

Defect (D) 19

Jumlah Unit (U) 10

Oportunity (O) 5

DPMO =((D/(UxO))x1000000

DPMO 380000

Sigma Level NORMSINV((1000000-DPMO)/(1000000))+1.5

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Sigma Level www.prodemyasia.com 1,8
 CONVERSION TABLE SIGMA LEVEL

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 SIGMA LEVEL FORMULA

Defect (D) 19

Jumlah Unit (U) 10

Oportunity (O) 5
=

DPMO =((D/(UxO))x1000000

DPMO 380000

Sigma Level NORMSINV((1000000-DPMO)/(1000000))+1.5

Sigma Level 1,8

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 Latihan Menghitung DPMO 37

37
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 38

----------------------------- END OF PART-1 -------------------------------------

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Thanks

Terimakasih

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