6SIGMA——黑带培训教材.ppt

Six SigmaBlack Belt TrainingIntroduction to Six sigmaA Data Driven Analysis and Scientific Approach to A Data Driven Analysis and Scientific Approach to Business Excellence.Business Excellence.用用6 6西格马数据驱动和科学方法来达致营运卓越。西格马数据驱动和科学方法来达致营运卓越。6 S I G M A Topics of discussion 讨论课题Introductory To Six Sigma Breakthrough Improvement Strategy.6 Sigma 突破性改善战略入门。nHistory of six sigma 六西格马的发展历史Linked stock performance to the deployment of Six sigma -GE 通用电气将六西格马与公司的效益联系在一起where does industry normally stand?各行业的西格马值处于什么位置？nHow Six Sigma being carried out and its application!六西格马的展开及其运用！Six Sigma deployed through projects.通过做项目推行六西马 Key elements of a well-defined Six Sigma project 一个定义完善的六西格马项目是关键因素.Topics of discussion 讨论课题nHow Six Sigma helped us to achieve our objective?六西格马 怎样帮助我们实现既定目标?Why Six Sigma?为什么是六西格马？Vision,philosophy and Strategy 目标，理念和战略Breakthrough thinking of Six Sigma is to reduce variation.六西格马的突破性思维是减少变异nSix Sigma s definition 六西格马的定义Is 99%good enough?99%的合格率足够好吗？Six Sigmas Performance Target 六西格马水平的绩效目标3 sigma vs 6 sigmas process -Throughput yield 3西格马 vs 6西格马过程-直通率 Sigmas definition -Practical meaning vs Math definition 西格马的定义-实际意义和数学意The focus of Six Sigma 六西格马的焦点Topics of discussion 讨论课题nSome Six Sigma Terminology 六西格马术语六西格马术语Six sigma process -DMAIC approach 六西格马过程-DMAIC 进阶改善策略和方法 DMAIC improvement strategy is to find the vital few leverage KPIVs.DMAIC 改善战略是为了找出少量的输入变量 Data driven analysis 完全建立在数据之上的分析 The role of measurements 测量发挥着重要的作用DMAIC phrases and statistical Tools kit DMAIC和统计工具 define Measure 定义测量阶段 Analysis 分析阶段 Improve 改善阶段 Control 控制阶段Topics of discussion 讨论课题Six Sigma System and Deployment 六西格马系统和推广I.Deployment 推广nSix sigma deployment process 六西格马导入过程nSome important deployment observations 导入过程中的重要发现II.Roles and Responsibilities 六西格马的角色扮演nCross functional role 跨功能角色nSix sigma role 六西格马角色nCritical mass 关键群体（人数）III Six sigma DMAIC training 六西格马DMAIC 培训nPTAR learning process PTAR学习过程nDMAIC training for BB and GB DMAIC 黑带和绿带培训nTrainings commitment 培训的承诺Topics of discussion 讨论课题 Project selection Project selection 项目选择项目选择n nProject selections approaches -Flow Down/Up ApproachProject selections approaches -Flow Down/Up Approach 项目选择方法项目选择方法-由下至上由上至上由下至上由上至上n nHarvesting the fruits of Six Sigma Harvesting the fruits of Six Sigma 收获六西格马的成果收获六西格马的成果n nProject Authorization Project Authorization 项目授权项目授权n nThe focus of Six Sigma project The focus of Six Sigma project 六西格马项目的焦点六西格马项目的焦点Difference between Six Sigma Breakthrough Improvement and ISO/Difference between Six Sigma Breakthrough Improvement and ISO/QS Certification -Customers expectation QS Certification -Customers expectation 六西格马突破性改善同六西格马突破性改善同ISO/QSISO/QS认证之间的区别认证之间的区别-客户满意度的客户满意度的区别区别Six sigma Benefits Six sigma Benefits 六西格马的效益六西格马的效益Six Sigma in general Six Sigma in general 六西格马概要六西格马概要Six Sigma Quiz for executives Six Sigma Quiz for executives 六西格马高层管理层的测验六西格马高层管理层的测验“The problems we face today cannot be solved at the same level of thinking we were at when we created them.”“如果我们的思维能力还是停留在之前的层次上，那么我们今天所面对的问题就无法得到解决。”Albert Einstein 阿尔伯特 爱因斯坦 The history of Six Sigma 六西格马的发展历史Six Sigma founded by 六西格马源于“摩托罗拉必须导入六西格马，因为我们在市场竞争中不断被外国公司击败，这些公司能够以更低的成本生产出质量更好的产品！”Bob Galvin 摩托罗拉的经验n1978，一日本企业收购了摩托罗拉的电视机制造业务n1981年,摩托罗拉培训中心成立,定下了要在五年内达成十倍品质改善的目标,很可惜，各部门仍然保持各自衡量品质的公制.n1987年，公司决心全面推广六西格马,定下了四年品质改善百倍的目标,统一了衡量公司品质的公制,如DPPM,DPMO和Sigma,当时现状为4Sigma.n1988年,摩托罗拉公司赢得了美国全面优质管理奖(Malcolm Baldrige)后，6 Sigma概念开始普及n1992年，摩托罗拉，柯达，ABB,IBM 和德州仪器开始了黑带培训和角色扮演n19931995年，摩托罗拉聘请了四万新雇员，免去了面年40小时的品质培训，当时公司收入增长幅度为27%,品质水平为5.2Sigma,拥有60%的市场George Fisher 去了柯达n1998年，摩托罗拉在移动电话的市场占有率只剩下34%,而年增长幅度只有5%.Japan vs USA in world market shares 日本和美国的世界市场占有率USA Japan20%40%60%80%80%80%100%78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 SemiconductorsEquipmentsComputersSix Sigma Expansion 六西格马的发展n n1987 1987 92 92 Motorola Motorola n n1990 Six sigma Research Institute Consortium 1990 Six sigma Research Institute Consortium n n1990 93 Texas Instruments,IBM,Polaroid.1990 93 Texas Instruments,IBM,Polaroid.n n1994 Allied Signal.1994 Allied Signal.n n1995 General Electric 1995 General Electric n n1996 Intel,Citibank.1996 Intel,Citibank.n n1998 99 NEC,Sony,Samsung,Fiat,Nokia.1998 99 NEC,Sony,Samsung,Fiat,Nokia.Six Sigma is all about making money!六西格马是利润至上，获得高利润才是硬道理！Six Sigmas proven Track RecordAnnualized Savings Allied Signal$800 million General Electric$1 billion Polaroid$100 millionTexas Instruments$360 million So,what is a six sigma company?六西格马公司是怎样的？A company driven to achieve its vision by focusing on customers,A company driven to achieve its vision by focusing on customers,people and processes.people and processes.一家六西格马公司会把焦点放在客户，员工和过程上，持续朝一家六西格马公司会把焦点放在客户，员工和过程上，持续朝着所定下的远景目标迈进着所定下的远景目标迈进The three principal methods are:The three principal methods are:三种采用的主要方法是：三种采用的主要方法是：Customers,PeopleAnd Processes FocusedDMAIC improvement methodology Design For Six SigmaBusiness Processes ManagementSix Sigma Practitioners-GE六西格马的开拓者通用电气“Six Sigma is the most important initiative GE has evertaken its part of the genetic code of out futureleadership”“六西格马是通用电气所有大型推广项目中最具重要意义的.它将成为公司现在和将来的管理模式，同样运用于公司未来的发展中”Jack Welch,Ex-CEO for GE Six Sigma Practitioners-GE六西格马的开拓者通用电气Six Sigma companies tend to Six Sigma companies tend to do well in marketdo well in marketcapitalization.capitalization.实施六西格马的公司在市场实施六西格马的公司在市场资本化方面将会做的更好资本化方面将会做的更好Analyst may raise earningsAnalyst may raise earningsexpectation if a Six Sigma expectation if a Six Sigma initiative is made public.initiative is made public.公司对外宣布实施六西格马后，公司对外宣布实施六西格马后，市场分析家调高利润预测市场分析家调高利润预测General Electrics Stock Performance.通用电气的股票表现Where does industry normally stand?目前工业的正常水准在何处？7西格马程度1,000,000100,00010,0001,000100101PPMRestaurant BillsDoctor Prescription WritingPayroll ProcessingOrder Write-upJournal VouchersWire TransfersAirline Baggage HandlingPurchased Material Lot Reject Rate国内航线航空死亡率(0.43 PPM)(with 1.5 shift)世界一流一般公司 345621IRS-Tax Advice(phone-in)(140,000 PPM)So,where are you?那么，贵公司处于哪个那么，贵公司处于哪个水平呢？水平呢？What is Six Sigma?什么是六西格马？Six Sigma is a Culture and Language commonly used.六西格马是一种文化和共同语言.Strategy fail when culture doesnt adapt!企业的文化如果不改变，就会导致战略的失败！六西格马成败的因素美国著名的管理学家，霍德盖茨先生曾出：.当战略和文化发生冲突时,文化恒胜;2.当企业文化与变革的精神不相容时,变革的努力将遭到失败.What is Six Sigma?是么是六西马？突突 破破 性性 的的 方方 法法Define Define 定义定义Measure Measure 测量测量Analysis Analysis 分析分析Improve Improve 改善改善Control Control 控制控制Complete picture of Six Sigma DMAIC Approach?P PDefine Opportunities(project chart)MeasureSymptom/effect(Where are we)AnalysisProblem/Cause)(Screen and findThe root cause)ImprovePerformance(Solutions)Control KPIVs(Sustain the gain)Six sigma projects targeted at critical aspects of the business with opportunity for improvement assigned to full-time Black BeltsQFD Project planning/managementTools COQProcess mappingSeven QC toolsCause and Effe.AnalysisBrainstormingFMEACapability analysisMSACentral limitMulti-vari.analyHypothesis Normality TestTest for Equal Variances ANOVANon-parametricCorrelation TestRegression SPCPre-control MethodAlternative Control chartsError proofingVisual controlOrganization Learning Full factorial Center pointFactional-Factorial DesignBlockingTagaguchi Desi.Multiple LinearResponse surfaceEVOP Top management support,six sigma Infrastructure,Financial engagement,Customer-focused Data driven analysis,Common 6 sigmametrics,Commitment from BB,One same language,Complete culture/behavioral change,MOC六西格马DMAIC 战略的概括图?P P定义机会（项目章程)测量症状结果(目前状况)分析问题原因(根本原因）改善绩效水平(解决方案)控制 KPIVs(保持成果)六西格马项目以关键营运过程的改善机会为目标，由全职黑带实施QFD 项目策划和管理工具COQ过程图QC 七大工具因果关系分析头脑风暴FMEA过程能力分析测量系统分析MSA中央极限定理多变量分析假设性试验 正态检验均方差分析 ANOVA非参数检验相关性分析回归分析 统计过程控制预先控制图其他控制图防错图象控制组织学习系统思考全因子DOE 中央点部分因子分析障碍田口设计线形分析反应表面分析EVOP 高层支持，西格马结构；财务参与;客户焦点数据驱动分析;6sigma量度,黑带承诺;奖励和承认;文化/行为改变共同语言;变革管理(MOC)Application of Six Sigma.六西格马的运用.Is to reduce“defects”and.六西格马的运用就是减少缺陷，Six Sigma Defect is anything blocking or inhibiting a process orservice.六西格马缺陷缺陷就是任何阻碍或抑制过程或服务圆满完成的事物I forgot it(我忘记了）Ill correct it(我会改正）It takes too long(耗时太长）I didnt like it(我不愿意.)We are off schedule(我们延误了进度）It was a waste of time(这是在浪费时间）I dont have the answer for that(我没有答案）We are sorry,we are usually better than that（抱歉，我们通常不是这么差）Six sigma as a business strategy 六西格马做为一个营运战略 The goal of the Six Sigma business strategy is to make fewer mistakes in every aspect of our business六西格马营运战略的目标就是使营运过 程的每一个环节所犯的失误减至最小.from manufacturing to delivery 从制造到出货from paying suppliers to invoicing customers从供应商付款到与客户结帐from hiring to performance appraisals 从员工招聘至其工作绩效评定from taking a phone call to setting a travel itinerary 从电话预约到出差日程安排Basically ALL!所有的环节！As a business strategy,Six Sigma can help a company secure a competitive edge.做为一个营运战略，六西格马可以使一个企业保持竞争优势！How does Six Sigma make the difference?六西格马如何制造这些差别？nwhy Six Sigma?为什么是六西格马，而不是其他工具？nVision 远景nPhilosophy 理念nVehicle for 的工具customer focus 关注客户breakthrough improvement 突破性改善continuous improvement 持续改善people involvement 全民参与nAggressive goal 进取的目标nMetrics(standard measurement)公制（测量标准）nMethod 方法Ask yourself.are this the key objectives of your company?这些是贵公司的主要目标吗？n nImprove time to market for all products Improve time to market for all products 提高所有产品占领时提高所有产品占领时常的时间常的时间n nLead the industry in key technology Lead the industry in key technology 行业领先，技术领先行业领先，技术领先n nCreate world-class manufacturing processes Create world-class manufacturing processes 世界级的制造世界级的制造过程过程n nDevelop strategic supplier relationships Develop strategic supplier relationships 与供应商发展战略合与供应商发展战略合作伙伴关系作伙伴关系n nProvide best-in-class products and process quality Provide best-in-class products and process quality 制造质量一制造质量一流的产品流的产品n nBecome an employer of choice Become an employer of choice 成为员工首选的公司成为员工首选的公司What are we doing to achieve those objectives?如何实现这些目标？Six Sigma (DMAIC and DFSS)Lean Manufacturing 精益制造精益制造Supply Chain Management 供应链管理供应链管理Customer Relationship Management 发展客户战略伙伴关系发展客户战略伙伴关系Balance Scorecard 平衡积分卡平衡积分卡 Many others 其他其他Why are we pursuing Six Sigma?为什么追求六西格马？We recognize the need for an improved quality management system and .我们迫切需要一个最好的品质管理系统.There are various but.Six Sigma is the best!(updated,complete,comprehensive,structured,systematic,quantifiable and scientific approach)我们有很多选择，但六西格马可算是最先进，完整，完善，组织化，系统化，量化的科学方法6 Sigma Vision 六西格马远景The vision of Six Sigma is to delight customers by is to delight customers by delivering world-class quality products through the delivering world-class quality products through the achievement of six sigma levels of performance in achievement of six sigma levels of performance in everything we doeverything we do.六西格马远景就是在每一件事中，在每一层次就是在每一件事中，在每一层次都达到六西何马水准，为客户提供世界级品质水都达到六西何马水准，为客户提供世界级品质水平的产品，从而最大限度地满足客户的要求平的产品，从而最大限度地满足客户的要求Measure Everything That Results In Customer Satisfaction 对所有影响客户满意度的因素进行测量对所有影响客户满意度的因素进行测量The customer supplier interaction 客户与供应商的相互关系Above interaction is the famous“Need Do Interaction”!Above interaction is the famous“Need Do Interaction”!上面的关系就称为上面的关系就称为“需要和做的关系需要和做的关系”！CustomerQualityDeliveryPriceDefectsCycle timeCostSupplierAsking the customer:Kano Model 客户需求：Kano 模式nIt helps employees set priorities Dont work on Delighters Dont work on Delighters until Must Bes are in until Must Bes are in placeplacenIt helps you avoid the trap of thinking that“no complaints means customer satisfaction!”Delight Delight NeutralDissatisfiedMust beMust beMore is betterDelightersAbsent Fulfilled-Dr.Noritaki KanoExample of Kano Model:buying a carWhat happens if the“must bes”are absent but you have the“delighters”and the“more”is better?Delight Delight NeutralDissatisfiedMust beMore is betterDelightersAbsent Fulfilled Gas MileageLuggage space4 wheels Working engineLeather seatsAlloy wheels Metallic paintA loyal customer 忠实的客户 Loyal Customer Is one who rates a 5 inAll three areas.Customer willRepurchase fromYour organization Customer perceives Value relative to the competitionCustomer willRecommended The product Six Sigma Philosophy 六西格马理念The Philosophy of Six Sigma is to apply a is to apply a structured,systematic approach to achieve structured,systematic approach to achieve breakthrough improvement across all areas of our breakthrough improvement across all areas of our business.business.六西格马理念是透过应用有结构，系统的方法，使营运过程中所有的环节都达到突破性的改善whats the strategy:战略含义nknow whats important to the customer 了解客户重视的地方（CTxs)nReduce defects 减少缺陷nCenter around the target 以目标为中心nReduce variation 减少变异 variation is evil!变异是魔鬼Traditional view:“Goalpost”Taguchi view:Variation is the Taguchi view:Variation is the Mentality enemy Mentality enemy LSLLSLUSLUSL任何落在规格尺寸之外的产品，意味着质量的损失任何偏差均对社会造成损失Quality Concept 品质概念nQuality means conformance to requirements.品质意味着符合要求。nQuality improvement means minimum variability from the target.品质改善意味着把目标的变异减至最低。So attaining certification like ISO/QS vs six sigma can be understood as maintaining quality conformance vs achieving breakthrough improvement.Goal:Process centering and variation reduction 目标：过程置中和减少变异The Sigma Strategy 西格马战略nCharacterize(define,measure phase)特征描述（定义，测量阶段）nOptimize(analysis,improvement phase)优化（分析，改善阶段）nSustain and breakthrough(control phase,whats next?DFSSM,Lean or.)保持和突破（控制阶段，下一步，6西格马设计，精益生产或.)Breakthrough Strategy 突破性战略改善的速度是最大的区别！Why Implement Six Sigma now?为什么现在是实施六西格马的最佳时机？n“Nothing new”“无新东西”Most of the tools have been around for decades 大部分工具已出现了几十年Neglected due to difficulty and discipline 由于难度大和条文多而被忽视But 但是nWorld-wide competition and globalization 世界范围内的竞争和全球化Make neglect dangerous to us and lost of opportunities 使忽略变得危险并失去了很多机会nComputing resources 电脑资源Makes application possible 是应用变成可能hat is Sigma?什么是西格马（）例如：假设生产过程中其中一个工序是将金属却割成每个长度为10mm的产品当我们完成100个产品后，测量每个产品的长度，并将测量结果用直方图的形式表达，我们将会得到下列结果：平均值平均值1011=xN=9.8hat is Sigma?什么是西格马（）标准差值标准差值1011=(x)N-1=0.3272Before calculating Sigma quality level,you need to understand Probability for the whole area under the cure=1i e.Yield+Defect lower than LSL+Defective higher than USL=1.Defective rateYieldDefective rateZ LSLTargetMeanZ USLe-Application:Z Transform(using Excel function nReturns a Z(normalized)from a distribution characterized by mean and standard deviation.Standardize(x,mean,standard_ dev)=Z Example:STANDIZE(42,40,15)=1.333333nReturns the standard normal cumulative distribution function.NORMASDIST(z)=Probability Example:NORMSDIS(1.333333)=0.908789nReturns the inverse of the standard normal cumulative distribution NORMSINV(probability)=Z Example:NORMSINV(0.908789)=1.3333What is Six Sigma?什么是六西格马?标准差()-曲线形状数量长度 0.320.32将标准差降至最低，最好是0 0.430.43相对来讲，将平均值（）调整至接近目标值较为容易，我们最大的挑战是降低标准差（）What is Six Sigma?什么是六西格马?如果产品规格是：如果产品规格是：100.5 mm,100.5 mm,划线划线部分便是不合格产品部分便是不合格产品如果过程平均值是如果过程平均值是9.8mm,9.8mm,偏离了目标偏离了目标值值10.0mm),10.0mm),不符合不符合规格的产品就会增加规格的产品就会增加10.0LSLUSL不合格产品不合格产品10.0LSLUSL不合格产品不合格产品10.09.8What is Six Sigma?什么是六西格马?如果标准偏差值增加，如果标准偏差值增加，不符合规格产品数量不符合规格产品数量就会增加就会增加如果标准偏差值减少，如果标准偏差值减少，不符合规格产品数量不符合规格产品数量便会减少便会减少10.0LSLUSL不合格产品不合格产品10.0LSLUSL不合格产品不合格产品10.0Six Sigma Concept 六西格马概念A 3 Sigma process because 3 standard deviations fit between A 3 Sigma process because 3 standard deviations fit between target and Spec.target and Spec.