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 Topics
What is Six Sigma
Six Sigma is a problem solving methodology
Six Sigma is a Philosophy:-
Focus on Customer
Employee Engagement
Distaste the defecte and variations
Six Sigma is a Metric(a common yardstick for measurement of business process)
Six Sigma is a management tool it is also provide 3 frame work for process improvement initiative
DMAIC( Define Measure Analyze Improve Control)
DMAIC mostly used for the improvement initiative where we already have a existing process that need to be Improve for bette
performance

DMADV(Define Measure Analyze Design Verify)

This Frame work mostly used where a new product or process is need to be design.

DFSS(Design For Six Sigma)

DFSS has a objective to determine the need of customer and business to driven those needs into a product solution.

Six Sigma methodology says

Y = f(x)
Dependendent Independent
Output Input
Effect Cause
Symptom Problem
Monitor Control

Common Process Improvement Themes:-

Organizations are under pressure from their customers to improve upon there metrics they are accountable for.
common themes used to improvements are
Doing More for Less
Bottom Quartile Management
Assets Re-Use
Knowledge Error Database(KEDB) or IP Retention
Mistake proofing
Digitization

Various Ways to Commence a Project

VOC (Voice Of Customer)
Customer Esclation or complaint
Misses or contractual obligations
Lost business analysis
On a Positive note- Customer need
Voice Of Business/Process(VOB/VOP)
Some project may be triggered by the need of business/process such as Increase in sale, profit, market share etc.
any critical metric design to meet the customer requirement
Organizational metrics like revanue,profitibility, resource utilization etc.
Repeat business score
Need of process speed( TAT )
Cycle time reduction
Efficiancy or productivity of company assets
exess rework
Repeated Errors
Line balancing/Process bottleneck removal
Ops logs
Rampup time
Attrition
Absenteeism

VOIC(Voice of Internal Customer)

Cost of poor quality
Project around impact of poor quality
Reduction of First Time not right
Reduce the cost of rework

Rolled Throughput Yield

FTR/Y(First Time Right/Yield)
OTD(On Time Delivery)
RR( Return Rate):- Define as no. of returns or request for return
NPR( Number of Problem Reported):-Define as no. of customer originated problem reported in given time cycle

commonly used terminology in six sigma

Identify Customer
External Customer-
Internal customer-

VOC(Voice Of Customer):- VOC of customer is a stated or unstated requirement of a customer.

CTQ(Critical To Quality):- CTQ are the key measurable characterstics of a product/service, whose performance standard or
specifications must be in order to satisfy the customer
They align improvement or design efforts in order to customer requirements

Customer CTQ:- customer CTQ are customer needs or expectations which can be explain as
Customer responsiveness/communication
Marketplace competitiveness-product/price/value
ON Time, Accurate, and compelete customer deliverebles
Product/service technical performance
to determine project CTQs, the customer and their wants must be determined. CTQs characterstics are determined by the
customer

Define Phase:-
Identify the process need:- One of the important part of the six sigma project is project need identification itself.
project need could have triggered becouse of customer complaint, your inability to meet the customer requirement, high cost
of poor quality, FTNR score being Low, misses on OTD

Identify Stackholders
Gather stackholders voice
Once the project need is identify, one should identify stackholders associated with it and seek their perspective on the same
issue.

Element of project charter:-

Business case:- business case must be highlighting the challenges at hand and must be create sense of urgency.
The consequences of not completing project must be in-keeping with what impact the sponser most.

Problem/Opportunity Statement:- for the problem or opportunity statement one must mention duration of the data analyzed
Goal Statement:- Defination of improvement the team is seeking to achieve, it must be realstic not aggressive.

Scope:- Scope statement is to clearly describe and gain agreement on the logical boundries of the project. It is important for
the project that who so ever Is involve in the project and also those who are intersted in the success of the project must be on
the same page boundry.
It must be clear what is inscope and what is out of scope.
Communication Plan:- project related communication protocols must be establish to ensure timely, correct and right
information reachses to right audience in desire format.

Milestone:-Milestone are commonly used for project monitoring purpose, it in likely deshbord to monitor project activities

Roles & Responsibility:-A tool to determine the individual or group whose commitment is essential for project success.
ARMI model- A-Approval, R-Resource, M-Member, I-Interested party,
RASIC Model- R-Responsible, A-Approve, S-Support, I-Inform, C-Consult,

Basic Statistics:- Statistics is defines as "Collection , organization and interpretation of the data.
Types of Data
Countinuous:- Countinuous data can be change into other form without loosing its original value
Ex-1 KG=1000 gm, 1 KM= 1000 Mtr.
Discreate:- Discrete data cannot be change into any other form.
Pass/Fail, Right/Wrong, 0/1( binary data, % data, nominal data ordinal data

Measures of cental tendency(Mean, median, Mode):- central tendency tells you how tightly your data cluster with central
point.
Mean:- mean is a arithmetic average of a data set, Mean is use when data is normally distributed. Mean is sensitive towards
extream values
to calculate mean {=average(data set)} formula can be use
Median:- The median is also a measure of central tendency, (median is the central position of a data set when it is set in either
in ascending or discending order, median is not sensitive towards extream values.
If data set is odd then central value of the data set will be the median
If data set is a even data then average of middle to value of data set will be the median

Mode:- The mode of a data set is the value which repeat most frequently in complete data set.

Measures of Spread(Range, Variance and Standard Deviation)

Spread/Dispersion:- The extend to which the observations in a sample or population vary from its mean is called dispersion of
the data.
Dispersion tell us how data is distibuted around its central point.
variation is often depicted graphically with histogram

Range:- The range is define as difference between the maximum and minimum value of a given data set.
If Xm is the maximum value and X0 is the minimum value then =Xm-X0 will the range of given data set.
To calculate Xm (=max(data set) and to calculate the X0 (=min(data set)
the range can be zero but can never be nagetive

Variance:- Variance tells you how far off the data value value from the over all mean, to calculate the mean ensure to deal with
positive no's.
calculate the mean of all data point, Xbar
calculate the difference between the mean and each data point
square those figures for all data point.

Standard Deviation:- Standard deviation is the average distance of the each data point to the mean of the data set.

to calculate the standard deviation simple calculate the variance of the data set and take the square root of variance.

Quartile:-The quartile in a given set is the three values which devide the complete data set into 4 equal groups. Each quarter
represent a fourth of data set being sample.
Q1, Q2 & Q3
to calculate the quartile (=quartile(data set,3) for Q3, (=Quartile(Dataset,1) for Q1,

Stability Factor:- It is again a measure of data variation of the mid 50% of the data set.
SF closer to 1 means that Q3 and Q1 are closer to each other, Exact 1 means Q3 and Q1 are exactly the equal.
SF closer to 0 means Q3 and Q1 are far away from each other.

Inter Quartile Range(IQR):- It represent the mid 50 % of the data set. This is used a measure of variance of the centre % of the
data.
IQR=Q3-Q1
4.

Normal Distribution:- Normal distribtion helps us to identify whether a given data set is normally distributed or not, Its mainly
use in continuous data set excepted some forms of discrete data such as binominal data.
Normal distribution says :-
68% of process (data value) will fall within +/- 1 Standard deviation from the mean.
95% of the process (data value) will fall within +/- 2 standard deviation from the mean
99% of the proccess (data value) will fall with In +/- 3 standard deviation from the mean
But it cannot be 100%

General Charecterstics of normal data

Uni model( Distribution will have a single peak)
Peak will fall on its mean
Mean, Median and Mode will have the same value
mean will devide the bell curve symmertically
Both tail will never touch the X axis

Measure Phase:-
the measure phase of six sigma project is the stage where we commence the exercise of collection of data to be use in six
sigma project. Speaking broadly the following are the activities to be done as a part of measure phase.

Identify the CTQ characterstics for the project

Define in discussion with stackholder the CTQ matric which shall be studied.
The acceptance critaria (Goal Statement) shell be in line with CTQ characterstics identify
remember CTQ matric should assist in analysis.
choose the matric carefully, should not minimize the data element collected.
Ensure that CTQ characterstics is relevant.
In countinuous data set there must be 30 data point available for any conclusion (Recommended)
Continuous data provide better overview over discete data
If countinuous data is not available then preffer numeric data in discrete data type.
there must be 60 data points available in discrete data type (recommended)

Create the Data Collection

Ensure the operational defination of CTQ characterstics must be understand by all.
You should be aware of what data is required by you from any of the concern department which can be collect in one go by
telling them what you required, like time cycle of data, data point, etc..

Data Collection Plan:-

Creation of a data collection plan is an critical aspect of the project success. It is critical that everyone involved in the project
success metric and the other element.

Operational defination:- You should define the method of calculating the data for the project.
Operational defination is a precise description that tells you how to get a value of the characterstics (CTQs) you are trying to
measure.
to remove the ambiguity so that everyone has the same understsnding
to provide a clear way to measure the characterstics
Identifies what to measure
makes sure that no metter who does the measuring, the result are essentially the same
must be useful for both customer and you
Define performance standard
The standard time or standard process which is mention in the goal statement as target. A performance standard is the
requierments or specifications of the customer on a specific CTQ.
It answer the question:-
What customer wants?
what is a good process/product?
what is defect?

Specification limit:

Specification limit are set in order to divide customer satisfection from customer dissatisfection while the exact limit may not
be explain by the cutomer, their specification limit define as what customer call a defect.
Specification limits are the upper and lower limit of a process/product, 0 & 100 % will not be count in spec. limit

Defect Defination:-
Any data point, process/product which breaks the upper or lower specification limit will be consider as defect, becouse in that
case that will not meet customer requirement.

Other Item on the data collection plan:-

Data type-countinuous or discrete.
Formula to be use
data item needed
unit of measurement
no. of decimal to be use
equipment to be use
calibration information for the equipment
Database or container to be use for data storage
If the database/cointainer is new, what is the date of creation
who will be responsible for the same
Any training required for the data collection
operator information

Measure System Analysis

Measurement error is everywhere, start with assumpition that every piece of data you see is wrong or have variation, becouse
of six sigma professionals you are bound to believe that nothing in this world can be measure 100 % accurately. You need to
figure out the diffrence between the actual and the observe value.

observed variation = true variation +_ Measurement error (variation caused by the measurement system)
It is important to identify the variation caused by measurement system
needed to decide wheather diffrence does matter.

Possible source of variation

true process variation
variation added by measurement system
To able to address the actual process variation, the variation due to measurement system must be identify and seprate from
the process variation.

Measurement System Analysis Decision Tree

Discreate Data:-
Conduct Attribution Agreement Analysis (AAA) or Effectiveness Efficiency

While you are intent to study the measurement system for discrete data, one method that could be deployed is Attribution
Agreement Analysis.
While doing AAA you could set out to study the effectiveness and efficiency of you measurment system
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Observed process variation
 Actual process variation Measurement variation

Long Short
term term within Variation
process process sample due to
varation variation variation Gage

Precision
Accuracy( (pure
bias) error)

Repeatibil
ity
Measurement variation

Variation
due to
operator

Reproduc
ibility

Stability Linearity
(time (value
depende depende
nt) nt)