Download Que es Six Sigma

Edson Silveira de
Oliveira
Master Black Belt in Six Sigma
March, 2004
DPC - South America
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Six Sigma Program
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Contenido
• Quien Somos: “Du Pont”….….”DuPont Performance Coatings”
• Que es Six Sigma ?
• Por Que Decidimos Implementarlo ? Valores ?
• Cómo lo aplicamos y donde?
• Cómo funciona?
• En que estamos trabajando en Du Pont?
• Ejemplo...
DPC - South America
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Six Sigma Program
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Quien somos: “Du Pont” ?
Du Pont es una compañía científica mundial, conocida por
algunos de sus inventos que revolucionaron al mundo en el
siglo XX y que ofrece productos y soluciones en mercados
como:
•Alimentos y Nutrición
•Construcción
•Textiles
•Transporte
•Electrónicos
•Salud
DPC - South America
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Six Sigma Program
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Du Pont Performance Coatings
Es el mayor fabricante a nivel mundial en Pinturas Automotrices e
Industriales. Creada en 1999 a partir de la fusión de DuPont
Automotive Finishes y Herberts (División de Pinturas de Hoescht).
Posee operaciones en 36 países a nivel mundial que suministran
pinturas automotrices e industriales en los 5 continentes.
Divisiones
DPC - South America
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Six Sigma Program
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Du Pont Performance Coatings
Venezuela
Pinturas Automotrices e Industriales
Mercado Automotriz
(Region Andina)
OEM
DPC - South America
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Six Sigma Program
REFINISH
5
Contenido
• Quien Somos: “Du Pont”….….”DuPont Performance Coatings”
• Que es Six Sigma ?
• Por Que Decidimos Implementarlo ? Valores ?
• Cómo lo aplicamos y donde?
• Cómo funciona?
• En que estamos trabajando en Du Pont?
• Ejemplo...
DPC - South America
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Six Sigma Program
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What is Six Sigma ?
“Six sigma quality means the virtual
elimination of defects from every
process, product and transaction in
our company…
It is a key part of how we will do
business well into the next century...
However, the real impact of Six
Sigma is that it is a business
management process and not just a
quality metric.”
DPC - South America
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Six Sigma Program
Chad Holliday
Chairman & CEO
DuPont Company
February 26, 1999
7
Six Sigma is a ...
• Vision
– Practically flawless execution
• Philosophy
– “The way we do work.”
• Business Improvement & Development
Methodology
– Touches all facets of the business
– Measurable financial impact
• Performance Metric / Goal
– Performance measure
– Yardstick
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Six Sigma Program
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Benchmarking Results
IRS tax advice
(phone in)
1,000,000
Doctors’ prescription writing
100,000
restaurant bills
10,000
airline baggage handling
1,000
DuPont
average
100
DuPont safety
world class
performance
10
1
2
3
4
5
6
7
Sigma Scale of Measure
DPC - South America
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Six Sigma Program
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Evolution of Six Sigma in the USA
• Air Products
• Honeywell
• Johnson Controls
• Maytag
• Praxair
• Ford
• Johnson & Johnson
• DuPont
• Dow Chemical
Six Sigma was originally developed for parts
manufacturing, to provide a quality-driven
competitive advantage…
funded full
development
of
methodology
1985
• ABB
• Motorola
• TI
• IBM
• DEC
• Kodak
1992
current
benchmark
• GE
• AlliedSignal
• Siemens
• Compaq
• Seagate
• PACCAR
• Toshiba
• Nokia
• Sony
• Navistar
• Whirlpool
• Bombardier
• GenCorp
• Siebe Foxboro
• Lockheed Martin
• John Deere
… and is now seen as a
key to growth in profits
& share price.
1995
2000
… then was expanded beyond manufacturing…
DPC - South America
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Six Sigma Program
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Contenido
• Quien Somos: “Du Pont”….….”DuPont Performance Coatings”
• Que es Six Sigma ?
• Por Que Decidimos Implementarlo ? Valores ?
• Cómo lo aplicamos y donde?
• Cómo funciona?
• En que estamos trabajando en Du Pont?
• Ejemplo...
DPC - South America
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Six Sigma Program
1
Valores de Seis Sigma
1- Enfoque en el Cliente
“La única garantía para nuestro negocio es un cliente satisfecho”
2- El Cliente define la Calidad
Darle al cliente lo que quiere, ni más ni menos.
3- Medición es la Clave
No sabemos lo que no medimos.
4- Actuar con pruebas
Tomar decisiones en base a data
5- La Variabilidad es el Enemigo
Bien la primera vez = Menor costo
6- Aumento del Conocimiento Colectivo
Personas con conocimientos y herramientas para la mejora continua
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Six Sigma Program
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Satisfying the Stakeholders
Who are they and what do they want ?
• Customers – maximum value in offering relative to cost.
• Employees – wages, benefits, job security.
• Shareholders – profit  dividends and share price
appreciation.
• “The only source of a paycheck is the customer.”
• The customer is the common denominator and the key to
satisfying the needs of all of our stakeholders !
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Six Sigma Program
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Purpose
ID Customer Needs
Stakeholders:
• Customer
- can be internal, external, or both !
• Employees
• Shareholders
ask & listen
Address Customer Needs
improve or develop the
process through SIX SIGMA
Achieve Customer Satisfaction
Gain Competitive Advantage
increase revenue
&/or reduce cost
End Result: Sustainable Profit
All stakeholders’ needs will be met when the customers are satisfied.
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Six Sigma Program
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Unleashing Potential with Six Sigma
Risk
Risk vs Knowledge
Art
• chaos
• firefighting
• waste
• fear
• “change averse”
Move along curve using 6s
• enhance process knowledge
• exploit to reduce defects and/or
create new offerings
Science
• data
• discipline
• good decisions
• confidence
• innovative
Knowledge
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Six Sigma Program
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Existen buenas oportunidades de Reducción de Costos!!!
Costos de Baja Calidad
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Sigma
Costos
•
•
•
•
•
<10% de las Ventas
10-15% de las Ventas
15-20% de las Ventas
20-30% de las Ventas
30-40% de las Ventas
Six Sigma Program
6 sigma
5 sigma
4 sigma
3 sigma
2 sigma
1
Value of Six Sigma
Improvement Projects Example
G1 sales price
profit
healthy
business
price erosion
profit
profit
total cost of
goods sold
cost of poor
quality
cost of poor
quality
theoretical
cost
theoretical
cost
without 6s
DPC - South America
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Six Sigma Program
COPQ
Theoretical
theoretical
cost
with 6s
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Value of Six Sigma
Development Projects Example
G1 sales price
profit
price erosion
profit
profit
cost of poor
quality
total cost of
goods sold
DPC - South America
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Six Sigma Program
healthy
business
Develop the offering so
there is “no” COPQ
profit
theoretical
cost
theoretical
cost
without 6s
with 6s
theoretical
cost
1
Value of Six Sigma
Top Line Growth Example
nonstrategic
total market
nonstrategic
balance of
market
market
share
nonstrategic
potential
strategic
potential
market
share
new share
market
share
market
share
new share
with 6s
DPC - South America
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Six Sigma Program
potential
strategic
nonstrategic
potential
market
share
market
share
market
share
with 6s
without 6s
2
Contenido
• Quien Somos: “Du Pont”….….”DuPont Performance Coatings”
• Que es Six Sigma ?
• Por Que Decidimos Implementarlo ? Valores ?
• Cómo lo aplicamos y donde?
• Cómo funciona?
• En que estamos trabajando en Du Pont?
• Ejemplo...
DPC - South America
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Six Sigma Program
2
Which Business Function Needs It?
HR
IT
supply chain
R&D
manufacturing
engineering
admin
sales &
marketing
•
•
•
•
DPC - South America
QA
mergers &
acquisitions
All facets of the business !
Every task is a process.
Every process has at least one customer and one output.
Six Sigma focuses on improving the outputs !
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Six Sigma Program
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Contenido
• Quien Somos: “Du Pont”….….”DuPont Performance Coatings”
• Que es Six Sigma ?
• Por Que Decidimos Implementarlo ? Valores ?
• Cómo lo aplicamos y donde?
• Cómo funciona?
• En que estamos trabajando en Du Pont?
• Ejemplo...
DPC - South America
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Six Sigma Program
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The Six Sigma Process – High Level
1. xxxxxxxxx
2. xxxxxxxxx
3. xxxxxxxxx
4. xxxxxxxxx
5. xxxxxxxxx
6. xxxxxxxxx
business strategy
ideas –
internal / external
“evergreen”
project list
Six Sigma Projects
1. xxxxxxxxxxxxx
2. xxxxxxxxxxxxx
3. xxxxxxxxxxxxx
project selection
translation
realize benefit
DPC - South America
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Six Sigma Program
project validation
DMAIC &
DMADV
Six Sigma teams
2
Projects Definition
CTX Flowdown
Y
y
y
CTS
y
y
CTQ
y
y
y
y
Y
CTP
MEASURE
ACTUAL PERFORMANCE
GOAL
BENCHMARKING
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l
l
l
Six Sigma Program
Projects
l
l
l
l
l
l
l
l
l
2
Six Sigma Process – Project Level
Business
Solution
Business
Problem
Practical
Problem
Statistical
Problem
Statistical
Solution
Practical
Solution
Within a Six Sigma Project we…
• Translate a business challenge to a defect elimination, variability reduction
problem, or development need
• Formulate this problem as a statistical problem
• Solve the statistical problem using tools and techniques taught in this
course (or suggested by your MBB)
• Convert the statistical learning into business benefits and actions.
• Ensure gains are sustained long after project completion.
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Project Types & Methodologies
Baseline Projects
Design Projects
Improvement Projects
DMAIC
Define
Measure
Analyze
Improve
Control
DMADV (DfSS)
Methodology Spectrum
Define
Measure
Analyze
Design
Verify
Top Line Growth Projects
Click link for more information on project types 
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Six Sigma Program
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DMAIC – Phases & Deliverables
D1:
D2:
D3:
Project CTQ’s
Project Charter
Process Map
M4:
M5:
M6:
M7:
M8:
M9:
Project Y
Performance Stds
Data Collection Plan
Project Y Data
Process Capability
Improvement Goal
A10: Prioritized List of X’s
A11: List of Vital Few X’s
A12: Financial Opportunity
C15: Sustained Solution
C16: Project Documentation
C17: Translation Opportunities
I13: Proposed Solution
I14: Piloted Solution
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Six Sigma Program
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DMADV – Phases & Deliverables
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Six Sigma Program
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Design for Six Sigma is...
DfSS is the set of Six Sigma
philosophies, principles, methods, and
tools applied to development work.
Typically DMADV is associated with
DfSS.
DPC - South America
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Six Sigma Program
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It All Starts with the Customer
X’s
(process)
Inputs
Supplier(s)
X’s
(inputs)
Output(s)
Y’s
Process
Customer(s)
CTQ’s
•
•
•
DPC - South America
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Six Sigma works from RIGHT to LEFT !
– ID customer and find out what’s critical for them (CTQ)
– Define what process output(s) (Y’s) most closely relate to the CTQ
– Determine what process controls and inputs (X’s) most affect the output
– Identify modes of operation in the X’s to dramatically improve Y and delight the
customer
Final solution = optimal arrangement and control of the X’s
Old school solution = Inspect Y and throw out the bad!
© 1994 Six Sigma Academy
Six Sigma Program
3
Dynamics of Execution Strategy
The “Funnel Effect”
Process Map
30 to 50 Inputs (X’s)
C&E Matrix & FMEA
Multi-Vari Studies
10 to 15 X’s
Hypothesis Testing
8 to 10 X’s
Screening DOE’s
4 to 8 X’s
DOE’s / Trial Exps
Control Plan
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Six Sigma Program
3 to 6
Vital X’s
Optimized Process
3
Personal Six Sigma
(DPC South América)
Master Black Belt
(South America)
(1)
DPC - South America
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Six Sigma Program
Champion Deployment
(South America)
(1)
Black Belts
(Venezuela)
(2)
Black Belts
(Brazil)
(4)
Green Belts
(Venezuela)
(9)
Green Belts
(Brasil)
(100)
3
Six Sigma Methodology: Summary
• Disciplined, Data-based approach
• Focuses on the customer and critical outputs
• Works upstream to control process X’s instead of
relying on inspection and testing
• Attacks variation, defects and “hidden” costs /
wastes
• Directly affects quality, cost, cycle time and
financial results
• Ensures a predictable operation
DPC - South America
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Six Sigma Program
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Contenido
• Quien Somos: “Du Pont”….….”DuPont Performance Coatings”
• Que es Six Sigma ?
• Por Que Decidimos Implementarlo ? Valores ?
• Cómo lo aplicamos y donde?
• Cómo funciona?
• En que estamos trabajando en Du Pont?
• Ejemplo...
DPC - South America
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Six Sigma Program
3
Ideal First Six Sigma Project
• Historical and current data accessible
• Good fit with Six Sigma methodology & tools
• Strong support/sponsorship in place
– Clearly linked to real business need
– Part of your ongoing work
• Not capital intensive
• Achievable in 4 - 5 months for improvement; 6-10
months for development (i.e. turnover to process
owner)
• Clearly quantifiable savings or revenue enhancement,
with minimum risk to external factors
• High probability of success
DPC - South America
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Six Sigma Program
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Baseline Projects
Methodology
•
DMAIC
Process
•
Existing
Approach
•
Broad or Focused - situational
CTQ’s  Y’s
•
1 or more Y’s - situational
Focus
•
Improvement; Defect Identification & Reduction
Variation
•
Primarily Special Cause
Duration
•
2 to 4 Months
Output
•
Stable Process, “Quick Hit” Imps, & “Child” 6s Project Charters
Benefit
•
Varied (none to $MM’s)
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Improvement Projects
Methodology
•
DMAIC
Process
•
Existing
Approach
•
Focused
CTQ’s  Y’s
•
1-2 Y’s
Focus
•
Improvement / Defect Reduction
Variation
•
Special and Common Cause
Duration
•
4 to 6+ Months
Output
•
Improved Processes with Enhanced Capability
Benefit
•
> $175K PTOI (Pre-Tax Operating Income)
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Examples of Improvement Projects
• Cycle Time Reduction Projects
– Reduce the time required to complete manufacturing
processes or transactional activities. Example: Return empty
railcars to supplier faster to reduce railcar storage
(demurrage) charges.
• Defect Reduction Projects
– Reduce or eliminate defects in quality. Example: Eliminate
defects in pigment color.
• Consumption Reduction Projects
– Reduce or optimize the consumption of costly raw material,
contract service or energy. Example: Reduce amount of
Lime required for neutralization.
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Six Sigma Program
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Development Projects
Methodology
•
DMADV or DMAIC (DMADV more typical)
Process
•
New or Redesigned
Approach
•
Broad and Systemic
CTQ’s  Y’s
•
Many Y’s
Focus
•
Design or Re-Design
Variation
•
Primarily Common Cause
Duration
•
6-12 Months (capital developments are longer)
Output
•
6s Process, by Design
Benefit
•
Typically Large & Often Soft
DPC - South America
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Six Sigma Program
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Examples of Development Projects
• Cycle Time Reduction
– Reduce the time required to complete manufacturing
processes or transactional activities. Example: Design a new
bidding process for reverse auctions that reduces time to
completion by 3 days
• Defect Reduction Projects
– Reduce or eliminate defects in quality. Example: Develop a
new training program for operators that results in a reduction
in poor quality polymer
• Demand Creation Projects
– Develop new marketing programs to create demand for an
existing product. Example: Work with customers and
partners to create new marketing plan for fire extinguishent
resulting in significant new sales
DPC - South America
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Six Sigma Program
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Definition of Top Line Growth
• The application of 6 Sigma to compel
customers to buy more, resulting in
increased value for DuPont and the
Customers. (official 6/02)
• TLG is a specific result area focused on
profitably growing revenue.
• Either DMAIC or DMADV may be used.
DPC - South America
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Six Sigma Program
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Top Line Growth Projects
Methodology
•
DMAIC or DMADV
Process
•
New or Redesigned
Approach
•
Either Narrow and Focused or Broad and Systemic
CTQ’s  Y’s
•
One Y or Many Y’s
Focus
•
Improvement, Design, or Re-Design
Variation
•
Special Cause and/or Common Cause
Duration
•
4 to 6+ for Improvement type TLG; 6+ for Development
Output
•
6s Process, by either Improvement or Design
Benefit
•
High $ Value and Hard $;
SBU Specific but typically > $500M
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Six Sigma Program
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Examples of TLG Projects
• Demand Creation Projects
– Develop new marketing programs to create demand for
an existing product. Example: Work with customers
and partners to create new marketing plan for fire
extinguishent resulting in significant new sales
• Defect Reduction Projects
– Reduce or eliminate defects in quality. Example:
Eliminate defects in pigment quality
• Platform Development Projects
– Develop an extension or upgrade to an existing process
or product to create a new product Example: ???
DPC - South America
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Six Sigma Program
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“TLG Focus Areas”
PTOI
TLG
• Product Development
• Application Development
• New Market Development
• At the Customer, For the Customer
Deliver TLG
Hard, soft, & one-time PTOI
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Six Sigma Program
TLG or Effectiveness
• Quality Improvement
• Service Improvement
• Pricing Process Improvement
• Selling Effectiveness
• Advertising/Communication
Improvement
• Branding Effectiveness
• Channel Effectiveness
• Sales Lead Management
Could deliver cost savings or TLG
Hard, soft, & one-time PTOI
4
Time for a Wrap-up
Can you…
• Describe what Six Sigma is in terms of its:
– purpose and value ?
– strategy and focus ?
– methodology ?
• Describe how DMAIC or DMADV works to
translate customer needs into high-performing
processes ?
DPC - South America
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Six Sigma Program
4
Contenido
• Quien Somos: “Du Pont”….….”DuPont Performance Coatings”
• Que es Six Sigma ?
• Por Que Decidimos Implementarlo ? Valores ?
• Cómo lo aplicamos y donde?
• Cómo funciona?
• En que estamos trabajando en Du Pont?
• Ejemplo...
DPC - South America
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Six Sigma Program
5
Proyecto Six Sigma
“MEJORAS EN EL SERVICIO DE
ENTREGAS A TIEMPO DE
PRODUCTOS OEM”
Green Belt: Carlos A. Calabrese S.
Status del Proyecto :Medición / Análisis / Experimentación
AGOSTO 2003
DPC - South America
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Six Sigma Program
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Resumen del Proyecto
Descripción del Proyecto:
Nuestra participación en el Mercado Andino es de
un 75%, lo que nos coloca como un proveedor
estratégico en la región..
En base a esto debemos garantizar en todo
momento un flujo contínuo de los materiales que
són utilizados en el proceso de pintura de los
vehículos.
Objetivo y Alcance del Proyecto:
Situación y Desempeño Actual:
sigma:
Y= 3,00 sigma (Short Term)
Meta del Proyecto:
sigma:
Y= 4,5 sigma (ST)
Incrementar el nivel de servicio a clientes OEM
Andinos.
Variables CTS (Y´s):
• % Servicio OEM
•Cambios de Producción por Fallas de Suministro.
•Cambios de Producción por Fallas de Calidad en
los Productos.
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Six Sigma Program
Beneficios:
• Mantener e Incrementar Participación en los
clientes OEM.
• Garantizar el flujo contínuo del proceso de
pintura de las ensambladoras.
• Fabricar los productos que realmente
requieren reposición de inventario en la línea.
• Garantizar 100% de satisfacción en Servicio
de Materiales Entregados a Tiempo.
5
Fase Diseño de Experimento
ESTRATEGIA:
• Se implementará un Sistema de Reposición de Inventario KAMBAN bajo la modalidad de
“Teoría de Restricciones”, controlado por un Semáforo:
Inventario OK
en almacén
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Six Sigma Program
Producción y
Reposición
Stock de
Seguridad
5
Fase Diseño de Experimento
Inventario 0
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Six Sigma Program
Consumo Zona
Amarilla
Stock de
Seguridad
5
Fase Diseño de Experimento
Inventario 0
DPC - South America
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Six Sigma Program
Consumo Zona
Amarilla
Stock de
Seguridad
5
Fase Diseño de Experimento
Inventario OK
en almacén
DPC - South America
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Six Sigma Program
Producción y
Reposición
Stock de
Seguridad
5
Fase Resultados
ACTUAL
Liberación de
Materiales
Ensambladoras
rojo
azul
PROPUESTO
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Six Sigma Program
5
Fase Conclusion
Hallazgos:
Variación entre las Cantidades de Materiales Solicitados y los realmente Consumidos.
Solicitudes Adicionales y Adelantos de Materiales frecuentes.
Retraso por parte del Cliente en las Entregas de las Liberaciones.
Mejora Planteada:
Implementación de un Sistema de reposición de Inventarios bajo el esquema KAMBAN
para el Suministro de Materiales a la Ensambladora.
Beneficios:
100% de Servicio en Entregas a Tiempo y Completo (100% Satisfacción del Cliente)
Mantener e Incrementar el % de Participación de Nuestros Clientes OEM
El Suministro dependerá de la demanda real (Consumo) de la línea.
Inventarios óptimos ajustados a las necesidades reales (Reducción de Inventario).
Optimización de los Recursos de Manufactura (Facilities & Personal) ya que el sistema de
planificación de la producción estará basado en las necesidades reales.
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