- Motorola developed the concept of Six Sigma in 1987 to improve quality standards and reduce defects. - Six Sigma aims to reduce defects to 3.4 defects per million opportunities by focusing on statistical process control and reducing variation. It was later adopted by other companies like GE. - The key purpose of Six Sigma is to make customers happier by meeting their requirements and reducing defects, while also increasing company profits through cost savings from quality improvements.

1. Introduction to Six Sigma Purpose of Six Sigma - To make Customer Happier and Increase Profits

3. Time Line 1985 1987 1992 1995 2002 Allied Signal Johnson & Johnson, Ford, Nissan, Honeywell Dr Mikel J Harry wrote a paper relating early failures to Quality. MOTOROLA General Electric

4. Question : Which company pioneered the concept of six sigma? GE Bombay Dabbawallas ASQ Motorola

5. Question : Which company pioneered the concept of six sigma? GE Bombay Dabbawallas ASQ Motorola

6. Pilot's Six Sigma Performance Width of Landing Strip 1/2 Width of Landing strip If pilot always lands within 1/2 the landing strip width, we say that he has Six Sigma capacity.

7. Pilot's Six Sigma Performance This is a very crude way of telling that when you perform in half the margin allowed to you, you may call it six sigma performance.

8. Question: You have to park your car where side margins are 6 inches on both sides, if your car is perfectly parked in center. What is your performance level when you find out that all the times you are able to park your car within 3 inches from the center and at any time the side margin is not less than 3 inches? Twelve sigma Six Sigma Zero Sigma Three sigma

9. Question: You have to park your car where side margins are 6 inches on both sides, if your car is perfectly parked in center. What is your performance level when you find out that all the times you are able to park your car within 3 inches from the center and at any time the side margin is not less than 3 inches? Twelve sigma Six Sigma Zero Sigma Three sigma

11. Question: How six sigma helps in retaining people? Because two times 3 σ is 6 σ Three sigma does not motivate. Sigma reduces stress level. By empowering them to solve their problems.

12. Question: How six sigma helps in retaining people? Because two times 3 σ is 6 σ Three sigma does not motivate. Sigma reduces stress level. By empowering them to solve their problems.

14. Question: What is the key purpose of six sigma? Do not bother about profits, just make customer happy at any cost. To make customer happy To increase profits (50% marks) To make customer happy and increase profits

15. Question: What is the key purpose of six sigma? Do not bother about profits, just make customer happy at any cost. To make customer happy To increase profits (50% marks) To make customer happy and increase profits

16. What can Six Sigma do ?

17. GE Six Sigma Economics (in millions) Source: 1998 GE Annual Report, Jack Welch Letter to Share Owner and Employees - progress based upon total corporation cost/ benefits attributable to Six Sigma.

18. Overview of Six Sigma CHANGE THE WORLD TRANSFORM THE ORGANIZATION GROWTH COSTS OUT PAIN, URGENCY, SURVIVAL Six Sigma a PHILOSOPHY Six Sigma as a Process Six Sigma as a Statistical Tool.

23. Question: How many defects per million opportunities make six sigma? 3.4 0.34 3400 34

24. Question: How many defects per million opportunities make six sigma? 3.4 0.34 3400 34 This is with long term shift of 1.5 sigma

30. Question: In the representation Y=f(X), which of these is X Headache Viral Infection Fever Cough

31. Question: In the representation Y=f(X), which of these is X Headache Viral Infection Fever Cough True, that is the cause of the problem.

32. Some Basic Concepts

34. COPQ v/s Sigma Level

35. Question: Which of the followings is "not" the Cost of poor quality? Cost of raw material Cost of lost customer Cost of inspections Cost of repair

36. Question: Which of the followings is "not" the Cost of poor quality? Cost of raw material Cost of lost customer Cost of inspections Cost of repair

40. Question: Critical to Quality(CTQ) related to? The needs of customer Meeting the specified requirements

41. Question: Critical to Quality(CTQ) related to? The needs of customer Meeting the specified requirements

45. What is Sigma? Have you ever - Shot a Riffle? - Played Darts? What is the point of these sports? What is the point of these sports?

46. Have you ever…. Jack JIM - Shot a Riffle? - Played Darts? Who is a Better Shooter?

47. Variability Deviation = Distance between observation and the mean(or average)

48. Variability Variance = Average Distance between observations and the mean squared Jack JIM 8 7 10 8 9 VARIANCE

49. Variability Variance = Average Distance between observations and the mean squared Jack JIM 7 6 7 7 6 VARIANCE

50. Variability Most Outcomes occur in the middle Fewer in the “tails” (lower) Fewer in the “tails” (lower) Even very rare outcomes are possible Even very rare outcomes are possible The World tends to be Bell – Shaped …

51. “ NORMAL” Bell Shaped Curve µ 1  -1  2  -2  3  -3  68% 95% 99.7% Normal distributions are divided up into 3 Standard deviations on each side of the mean Once you are that, you know a lot about what’s going on … That’s what Standard Deviation is Good for

54. Acceptable v/s Defective OFF - TARGET Another View Center Process Reduce Speed LSL = Lower Specification Limit USL = Upper Specification Limit LSL USL LSL USL ON - TARGET LSL USL LARGE VARIATION

55. More about Limits Cpk measures "Process Capability" If process limits and control limits are at the same location, Cpk = 1. Cpk  2 is Exceptional.

56. A Six sigma process Predictably twice as good as what the Customer wants 1  1  1  1  1  1  6  +6  -6  LSL USL 1 2 4 3 5 8 9 10 7 6 11

57. Process shift Allowed 1.5SD LSL USL 1 2 4 3 5 8 9 10 7 6 11 12 13 14 15 16 1.5SD SD = 1

58. Six sigma Measurement

60. DMAIC

62. DMAIC Approach D efine the customer, their Critical to Quality (CTQ) issues, and the Core Business Process Involved M easure the performance of the Core Business Process involved A nalyze the data collected and process map to determine Root causes and opportunities for improvement I mprove the target process by designing creative solutions to fix and prevent problems. C ontrol the improvements to keep the process on the new course D Define M Measure A Analyze I Improve C Control

63. Question: Why should there be a Control phase when Improvement is already done? Only for companies totally out of control It is a optional phase This is to maintain the gains This phase is as per the choice of Management

64. Question: Why should there be a Control phase when Improvement is already done? Only for companies totally out of control It is a optional phase This is to maintain the gains This phase is as per the choice of Management

70. People power Tell me, I Forget. Show me, I Remember. Involve me, I Understand.

71. 6 Sigma Training Master Black Belt Mentor, Trainer, and Coach of Black Belts and other in the Organization Black Belts Leader of teams implementing the Six Sigma Methodology on projects. Green Belts Delivers successful focused projects using the Six Sigma Methodology on tools. Team Members/ Yellow Belts Participates on and supports the project teams, typically in the context of his or her existing responsibilities.

73. Question: Is Black belt position a full time job in the company? False True

74. Question: Is Black belt position a full time job in the company? False True

84. Thank You