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Process Management Training Materials OSSS LSS Black Belt v9.0 - Control Phase Copyright Open Source Six Sigma, Inc. 1 Project Management Course Contents Class Presentation • 352 slide PowerPoint Presentation • Instructor Notes • 14 Templates OSSS LSS Black Belt v9.0 - Control Phase Copyright Open Source Six Sigma, Inc. 2 Project Management Course Contents Phase A- Introduction; Define and Measure Course Overview • Process Management • Basic Statistics • Cost of Poor Quality • Define Phase • Defining an Improvement Project • Measure Phase Part One • Measure Phase Part Two • X‐Y Matrix Analysis • Capability Analysis • Measurement System Analysis • Process Improvement Project OSSS LSS Black Belt v9.0 - Control Phase Copyright Open Source Six Sigma, Inc. 3 Project Management Course Contents Phase B – Analyze, Improve and Control Course Overview • Introduction • Defects, Defectives and Opportunities • Graphical Analysis • Lean Value Stream Analysis • Applying the 5S Principles • Introduction to Improvement Experiments • Poka‐Yoke Methods • Statistical Process Control • Control Charts • Tracking and Managing a Process • Finalizing Your Process Project OSSS LSS Black Belt v9.0 - Control Phase Copyright Open Source Six Sigma, Inc. 4 Project Management A SMALL SNEAK PEAK… OSSS LSS Black Belt v9.0 - Control Phase Copyright Open Source Six Sigma, Inc. 5 Project Management Understanding Process Variation s Sigma s Fact of Nature/Principle Law – No two things are alike; everything has variation. Too much variation causes inconsistency, defects and lack of predictability. Sigma Sigma is a Greek letter assigned to represent the amount of variation or inconsistency a measurable outcome exhibits. It is a universally accepted method for describing the magnitude of variation. s By using a mathematical or analytical approach, Sigma can be used to quantitatively describe several performance metrics: Sigma 1. Measure of quality 2. Measure of variation 3. Measure of capability of a process Copyright Open Source Six Sigma, Inc. Project Management Understanding Process Variation The X’s (Inputs) X1 X2 X3 X4 Y = f(X) The Y’s (Outputs) Process: “A Blending Of Inputs to Achieve Some Desired Output/Result” Y1 Y2 Y3 X5 1. There are numerous processes within a company to deliver value to a customer in the form of outputs (results) 2. Outputs can be measured, and measurement creates data 3. By collecting data, you start the assessment of how well a process performs and how performance compares to requirements Copyright Open Source Six Sigma, Inc. Project Management Understanding Process Variation The X’s (Inputs) The materials people equipment environ. The Y’s (Outputs) The things you measure as an indication of the success of the process. Verified ? Op i Op i + 1 Data for Y1…Yn X1 Y1 X2 Off-Line Correction Analysis Scrap Y2 X3 X4 Yes X5 No Correctable ? Copyright Open Source Six Sigma, Inc. Y3 10.16 10.11 10.05 10.33 10.44 9.86 10.07 10.29 10.36 9.87 9.99 10.12 10.43 10.21 10.01 10.15 10.44 10.03 10.33 10.15 10.16 10.11 10.05 10.33 10.44 9.86 10.07 10.29 10.36 CTQ = Critical to Quality: Any output variable of a process which exerts an undue influence on the success of the process or on meeting customer needs Project Management Understanding Process Variation The Y’s (Outputs) Y = f(X) (Process Function) Verified ? Op i Op i + 1 Data for Y1…Yn X1 Y1 X2 Off-Line Correction Analysis Scrap Y2 X3 X4 Yes X5 Variation – “Voice of the Process” Frequency The X’s (Inputs) No Y3 10.16 10.11 10.05 10.33 10.44 9.86 10.07 10.29 10.36 9.87 9.99 10.12 10.43 10.21 10.01 10.15 10.44 10.03 10.33 10.15 10.16 10.11 10.05 10.33 10.44 9.86 10.07 10.29 10.36 9.80 9.90 10.0 10.1 10.2 10.3 10.4 10.5 Average (Mean) Correctable Critical X(s): Any variable(s) which exerts an undue influence on the important outputs (CTQ’s) of a process Copyright Open Source Six Sigma, Inc. Frequency ? 9.80 9.90 10.0 10.1 10.2 10.3 10.4 10.5 Project Management Understanding Process Variation Average (Mean) Point of inflection There is a standardized way or a single number that is used to express the amount of variation that exists. It is called the Standard Deviation or sigma. s -6 -5 -4 -3 -2 -1 +1 +2 +3 +4 This is the mathematically precise way of calculating this value: +5 +6 s quantifies the spread (around the mean) of a process or product characteristic. Copyright Open Source Six Sigma, Inc. By now we understand that variation exists in everything. n i 1 (xi x) 2 n 1 Project Management Sigma Score – Standard Deviation At the point of inflection it is neither concave or convex Average (Mean) Point of inflection This part of the curve is concave down This part of the curve is concave up s -6 -5 -4 -3 -2 -1 +1 +2 +3 +4 +5 +6 Copyright Open Source Six Sigma, Inc. This is a mathematically precise and calculable spot that exists on a normal distribution of data. Its distance from the mean is the value of Standard Deviation, it represents the spread of the data. Project Management Sigma Score – Standard Deviation As the spread of the data (variability) increases from the item we have measured, we can see that the “point of inflection” moves further away from the Mean: Distribution One Distribution Two Distribution Three s s s The larger the Standard Deviation, the more spread there is in the data (variability). Copyright Open Source Six Sigma, Inc. Project Management Linking Sigma Score to Standard Deviation 99.7% 95% 68% Average (Mean) Frequency Point of inflection 1s -6 -5 -4 -3 -2 -1 +1 +2 +3 +4 +5 -6 +6 Sigma (s1 ):This quantity is used to quantify the spread (around a mean) of some process or product characteristic. Requirements – “Voice of the Customer” Data - VOP 10.16 10.11 10.05 10.33 10.44 9.86 10.07 10.29 10.36 9.87 9.99 10.12 10.43 10.21 10.01 10.15 10.44 10.03 10.33 10.15 -4 -3 -2 -1 Defects -5 -3 -2 -1 +1 +2 +3 +4 +5 +6 9.70 9.80 9.90 10.0 10.1 10.2 10.3 10.4 10.5 10.6 Percent Composition Copyright Open Source Six Sigma, Inc. +3 +4 +5 +6 Process Performance (Yields & Transactions) Defects -4 +2 Sigma’s from the Mean “Area Under the Curve” Sigma -6 +1 USL = 10.44 LSL = 9.96 10.16 10.11 10.05 10.33 10.44 9.86 10.07 10.29 10.36 -5 2 3 4 5 6 Process Capability DPM 308,537 66,807 6,210 233 3.4 Defects per Million Sigma level: The metric used to indicate the output performance of a process to some specification. Project Management Sigma Score – A Measurement of Capability Process Performance Measured in Sigma’s Sigma DPM 2 3 4 5 6 308,537 66,807 6,210 233 3.4 Process Capability Copyright Open Source Six Sigma, Inc. Defects per Million The outputs of any process can be assigned a Sigma Score. How is this done? You can calculate sigma one of two ways: 1. By knowing the variation of the process output you are interested in and comparing it to the customer’s requirements. 2. By already knowing the defective level from some source of information. Project Management Sigma Score – A Measurement of Capability Process Performance Measured in Sigma’s Sigma 2 3 4 5 6 DPM 308,537 66,807 6,210 233 3.4 Process Capability Copyright Open Source Six Sigma, Inc. Defects per Million 1. What was the percent defective from the dice process_______? 2. Translate that value to PPM using this example as a reference: An output is found to be 30% defective, calculate as follows” (30%/100%) X 1,000,000 = .30 X 1,000,000 = 300,000 PPM= A sigma score of just a little over 2. 3. Estimate the approximate Sigma Score of your dice roll performance (See table on next page). Project Management Sigma Score – A Measurement of Capability Sigma DPM Yield 2.0s 2.5s 3.0s 3.1s 3.2s 3.3s 3.4s 3.5s 3.6s 3.7s 3.8s 3.9s 4.0s 4.1s 4.2s 4.3s 4.4s 4.5s 4.6s 4.7s 4.8s 4.9s 5.0s 5.1s 5.2s 5.3s 5.4s 5.5s 5.6s 5.7s 5.8s 5.9s 6.0s 308,538 158,655 66,807 54,799 44,565 35,930 28,716 22,750 17,864 13,903 10,724 8,198 6,210 4,661 3,467 2,555 1,866 1,350 968 687 483 337 233 159 108 72 48 32 21 13 9 5 3.4 69.1462% 84.1345% 93.3193% 94.5201% 95.5435% 96.4070% 97.1284% 97.7250% 98.2136% 98.6097% 98.9276% 99.1802% 99.3790% 99.5339% 99.6533% 99.7445% 99.8134% 99.8650% 99.9032% 99.9313% 99.9517% 99.9663% 99.9767% 99.9841% 99.9892% 99.9928% 99.9952% 99.9968% 99.9979% 99.9987% 99.9991% 99.9995% 99.9997% Copyright Open Source Six Sigma, Inc. Process Performance Measured in Sigma’s 5.6 % Sigma DPM 2 3 4 5 6 308,537 66,807 6,210 233 3.4 Process Capability Defects per Million Project Management