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OF SIX SIGMA
(6) FOR
PROCESS IMPROVEMENT
Presented by: Larry Bartkus of Biosense Webster and Matthew Thompson of FCI Management Solutions
Goals
Introduction to Six
Sigma
Description
Philosophies Benefits Origin Myths Identify the five steps of DMAIC, the core of Six Sigma, and the logical flow from step to step. List tools and concepts useful in each step. Brief introduction to DMADV
Six Sigma
Description
Six Sigma is a quality program that, when all is said and done , improves your customers experience, lowers your costs, and builds better leaders. Jack Welch CEO GE Six Sigma is a proven set of tools and tactics used for process improvement, reduction of defects, and improved quality Six Sigma uses data and statistical analysis to zero in on root causes
2
2.5
Six Sigma Measurement
308,537
158,686
30% 16% 6%
3
3.8
66,807
10,724
1%
.6%
4 5 6
Six Sigma
Philosophies
When defects occur look to the process for the cause. Excellent processes will allow average people to consistently generate superior results.
Benefits
More loyal and satisfied customers (internal and external) Financial savings through improved efficiency and effectiveness Resolution of chronic problems
Origin
The late Bill Smith, a reliability engineer at Motorola, is widely credited with originating Six Sigma and selling it to Motorola's legendary CEO, Robert Galvin.
Myths
5 CONTROL
1 DEFINE 2 MEASURE
4 IMPROVE
3 ANALYZE
Phase 1: Define
Goal Define the projects purpose and scope and get background on the process and customer Output 1 5 A clear statement of the DEFINE CONTROL intended improvement and how it is to be measured 4 2 A high-level map of the IMPROVE MEASURE process A list of what is important to 3 the customer
ANALYZE
Project Charter
Define
Supplier
Input
Process
Output
Custom er
Level Build Plan Im proved Cycle Tim es /WIP Reductions Reduced QNCs Im proved Efficiency/ Im proved Com pliance
Sterilize
Ease of use Documentation mirrors process Operations Rapid Improvement Improved Product Build Documentation Consistency between documents Compliance to procedures
Reduce process related QNCs by 50%
Reduce QNCs
Mitigate opportunity for near miss events Create simplified process flow.
Define
Measure
Analyze
Improve/ Innovate
Control
Phase 2: Measure
Goal Focus the improvement effort by gathering information on the current situation
5
CONTROL
1
DEFINE
Output 4 Data that pinpoints 2 IMPROVE problem location or MEASURE occurrence Baseline data on current 3 process sigma ANALYZE A more focused problem statement
D M A
The system to collect information is already established. 100% of Scrap forms from Work Orders for all products are captured into a Yield Database. Scrap form (FORM633) has information as Lot Number, Date, Shift, Product Number, Defect Code, Defect Description, Potential Cause, Work Station ID, Catheter Number, Scrap Quantity, and is signed by operator and supervisor / engineer. Yield Database has information as Product Number, Date, Lot Number, Description, Lot Quantity, Reworks, Scrap in Line, and Scrap in QA.
Analyze
2.5
2.5
2.5
33 5
61 8
62 1
61 7
61 5
63 3
61 6 rm Fo
rm
rm
rm
rm
rm
rm
Fo
Fo
Fo
Fo
Fo
Fo
Fo
Form
Fo
rm
05 1
Components of Variation
100
% Contribution % Study Var
Percent
50
Gage R&R
Repeat
Reprod
Part-to-Part
S Chart by Operators
6 Operator 1 Operator 2 UCL=5.418 _ S=3.447 LCL=1.476 100 75 50
Burst by Operators
Sample StDev
4 2
Operator 1 Operators
Operator 2
Sample Mean
80
60
The total Gage Repeatability and Reproducibility is 12.38%, which is well below the acceptance criteria of less than or equal to 30% of the Total Variation. Measurement system is acceptable. The Gage R & R study is able to show that the burst tester is capable of detecting different parts being measured as shown from the data reported by two different operators measuring the samples.
Define
Measure
Analyze
Improve
Control
Process Capability-Current
Process Capability Sixpack of C before
I C har t
Individual Value
UCL=1.9437 1.8 1.6 1.4 LCL=1.2472 1 2 3 4 1.2 1.3 1.4 1.5 1.6 1.7 1.8 _ X=1.5955
LSL
0.2
0.0
C apability P lot Within S tDev 0.116076 Cp * C pk 1.34 Within O v erall S pecs O v erall S tDev 0.102049 Pp * P pk 1.52 C pm *
Values
DMAI2C
Capability Histogram
UCL=170.4
Mean
Range
Last 10 Subgroups
170.4
Values
Within StDev: 0.207647 Cp: 0.80 Cpk: 0.70 Overall StDev: 0.191131 Pp: 0.87 Ppk: 0.76
Capability Plot
Process Tolerance Within
I I I I I I I
Overall
I
Specifications
169.5 170.5
Subgroup Number
Phase 3: Analyze
Goal
Identify
5 CONTROL 4 IMPROVE
1 DEFINE 2 MEASURE
3 ANALYZE
D M A
1.25
Av erage per WO
Av erage per WO
1.28
Av erage per WO
1.48
1.20
1.38
1.15
1.28
1.10
1.18
1.05
1.08
PART NUMBER
PART NUMBER
PART NUMBER
Av erage per WO
1.20
Av erage per WO
1.20
Av erage per WO
1.2
1.15
1.15
1.10
1.10
1.1
PART NUMBER
D-1237-01-S
D-1237-02-S
PART NUMBER
PART NUMBER
Benchmarking - Internal
Strategic Advantage
Tier 4
Transforming
Tier 3
Integrating
Tier 2
Tier 1
Basic Presence
Searching
Communities Advanced Search Value-add tools Moderate Interactivity
Advanced Applications High Interactivity e.g. online forms Knowledge Mgt hub Primary Communications Vehicle Content Rich
Analyze
Features
Regression Analysis
Forecasted Demand 08/15/05- 07/15/05
Fitted Line Plot
Grand Total = 34329 + 193.1 Month 40000 39000 38000
S R-Sq R-Sq(adj) 2661.11 7.0% 0.0%
Grand Total
7% Increase in demand/year
Analyze
Design of Experiment
Analyze
Improve
Control
Phase 4: Improve
Goal Develop, pilot, and implement solutions that address root causes. Output Identification of planned, tested actions that should eliminate or reduce the impact of the identified root causes
5
CONTROL 4 IMPROVE
FMEA
1
DEFINE 2 MEASURE
3 ANALYZE
D M A
Improvement team created with members of Quality, Production, Engineering and R&D areas to propose and evaluate ideas.
Brainstorming tool was used to gather ideas on how to solve the problems identified. Ideas were evaluated per following criteria: feasible, high impact, easy, low cost, and quick.
D M A
PROBLEM
BRIEF DESCRIPTION
PROPOSED SOLUTION
Train associates on visual acceptance criteria. Add a new hole to apply PU to bond components once they are in place. Design a new fixture to hold Nitinol during burnishing.
Some acceptance criteria are not clear for associates. Lasso to tip method. Defective bonding of Compression Coil and Lasso Stem Prep. lasso stem method. Poor burnishing of Nitinol wire.
Rejection of good product exposes it to damage during rework operations. PU is applied before the components are in place and is partially removed during installation of components. Current burnishing method is not ergonomic causing associates make defects after some time.
ASSESSING RISK
An Example:
RISK 12. Support Plan not in Place Description
IntegWare does not want to put Biosense Webster in a position of being overly reliant for day-to-day level 1 support of the system after go-live. IntegWare typically suggests that we assume the role of a second level support for a limited number of hours per month. IntegWare suggests it is typical for Day-to-Day (level 1) support will be a highly resource consuming task for three-six months after golive. To use IntegWare for this might be an ineffective usage of the customer's resources. The project ownership should be transferred to the customer if at all possible. It would be a better usage of the customers resources to ask IntegWare to implement higher value added initiatives in PDM (such as developing PART/BOM configuration management features, JDE integration, etc.) To mitigate this risk, we have discussed a support concept at BWI. This will be a combo function between Doc services (they will handle basic application admin functions) and IM who will handle IT functions. Still need to setup support contract for IntegWare to support system. Celeste has added to the schedule a support contract for level 2 support from IntegWare.
MITIGATION
HIGH 5/2/03
$5 $4 $3 $2 $1
1.6 2 .5
$0 1 2 3 4
Compliance Cost
1 10 100
Define
Measure
Analyze
Improve/
Control
Pilot/Pilot Plan
Used Japan Custom line as a pilot Medium size production line Minimize the production Impact
Signals, Lights
Kanbans Cards
Performance Measures
Define
Measure
Analyze
Improve/
Control
Phase 5: Control
Goal Use data to evaluate both the solutions and the plans Validate that all changes adhere to all operating company change control, GMP, and compliance requirements Maintain the gains by standardizing processes Outline next steps for on-going improvement Output Before-and-After analysis Monitoring system Completed documentation of results, learnings, and recommendations
1 DEFINE 2 MEASURE
CONTROL
4 IMPROVE
3 ANALYZE
D M A
All new tooling, processes, clarifications, and visual aids documented in PIs. Creation of MOPXXX with all the quality criteria for Variable Lasso Deflection and Contraction performance. MOP003 updated with reference to new created MOPXXX. PU quality criteria documented in WSS001 and available in QA workbenches.
D M A
Scrap Produced
Yield Goal
Yield Actual
Individual Value
105
10
UCL=9.69
Moving Range
5 __ MR=2.97
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Observation
LCL=0
Individual Value
105 _ X=100.72
100
12 UCL=11.01
Moving Range
__ MR=3.37
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Observation 19 20 21 22 23 24 25 26 27 28 29 30
LCL=0
Define
Measure
Analyze
Improve
Control
Lessons Learned
Culture shock Resources Scope creep / Identifying the critical few Management buy-in of change of policies Time management & deliverables challenges J&J Goals too high for small operating company (CMM goal of Level 3 per J&J Corp Strategy) Difficult to measure compliance
Project Closure
Improvement
must be continuous, but individual initiatives and project teams come to an end. Learn when its time to say goodbye. Effective project closure weaves together the themes of: Project purpose. Improvement methods. Team skills and structures. Develop managerial systems to capture learnings and enable the organization to address system issues. Documentation and recognition are two critical aspects of project team closure. Celebrate!
DMAIC Pathway
Define
Measure
Analyze
Design
Verify/ Validate
DEFINE Develop the Business Case, Scope & Charter the Project MEASURE Gather & Quantify Design Inputs (Customer, Technical, Business, Regulatory) ANALYZE Develop and Investigate Conceptual Designs DESIGN Develop Detailed Product/Service/Process Designs VERIFY/VALIDATE Confirm design outputs meet design input requirements and ensure specifications conform with intended uses and users; Scale-up manufacture and release the product or scale-up and implement the new process; Finally, transfer to process owners
DEx Methodology
Team Charter
Opportunity Define
Business Case Opportunity Statement Goal Statement Project Scope Team Selection Project Plan
Generation 1 Generation 2 Generation 3 Vision Product/ Service Generation Technologies/ Platforms
8 Design Review 9 Develop Details 10 Simulation 11 Cost Analysis 12 Design Review 13 Procurement 14 Implementation
Qtr 4, 1999 Qtr 1, 2000 Qtr 2, 2000 Qtr 3, 2000 ID Task Name Sep Oct Nov Dec Jan Feb Mar Apr May JunJulAug Sep 1 ID Customers 2 ID Needs 3 ID CCRs 4 Review 5 Develop Concepts 6 High-Level Design 7 Capability
7 Correlatio n (I) Target goals 3 Characteristic/Measur es (how)(I) Theme 1 Need 1 Need 2 Theme 3 Measures (Hows) Customer needs (Whats) 1 4 Customer Requirem ents (V) Critical process characteristics (Hows) Measures (Whats) House Of Quality #2 6 5 Relationships (What vs. How) (I) How important Targets/Spec s(B)(I) Technical Evaluation (B) Importance (V) Cust omer Rati 2 ng (B) (V)
Measure
Need 7 Need 8
House Of Quality #1
Need 5
Creative Techniques
White
Red
Black
Blue
Green
Yellow
Analyze
Worke r 1
Non-Linear Thinking
Build on Ideas
Combine Ideas
Compare
Worke rs
Ins pe ctor 1
SYSTEM
Ins p e ctors
P1
M V1 M V2 Valves
Bilge Failure
FAULT TREE
System Failure
Proce s s 1
Early Failures
Card
P2 Bilge
Ins pe ctor 3
Proce s s 2
Re cord e r 1
Ins pe ct 2 Worke r 3
Pumps
Pump Failure
Valve Failure
Re cord e rs
Re corde r 2
Proce s s 3
Ins pe ct 3
Pump P1 Fails
Pump P2 Fails
Pump V1 Fails
Pump V2 Fails
Time (t)
Re corde r 3
(1 -
(1-Rv)2)
DesignProductionDelivery Processes
DesignProductionDelivery Processes
Supporting Processes
Products
Services
Design Elements
1. H\W Products 2. S\W Products 3. Services 4. Analyses 5. Information Systems 6. Processes and Methods 7. Human Resources 8. Site \ Facilities 9. Equipment \ Tools 10. Materials \ Supplies 11. Sales \ Marketing 12. Other Non-Technical
Verify/Validate
Start
Supporting Processes
Products
Services
Design
Type of Design
Type of Design
Discrete
Type of data ?
Continuous
Yes
No
No
Yes
No
Equal opportunity ?
Yes
Individual measurements Individual measurements or subgroups ? Rational Subgroups Individuals charts EWMA chart
UCL
Transfer
Act Check
Plan Do
Stable
(In control)
Upper Spec
Either/Or
Lower Spec
LCL
p chart
no chart
u chart
c chart
X, R or s chart
Yes
Yes
Lower Spec