Common cause variations always exist in process inputs
and outputs therefore it is in the best
interest of manufacturer to reduce these variations and optimize the output performance
as much as possible through various methods. This is also known as a continuous
quality improvement program (CIP) which focus on reducing defects which contributed by
common cause variations and/or bring the process to optimum level to produce
consistent good quality product. Six sigma methodology is a popular method use
for this purpose. This method warrants for systematic phase by phase approach of deploying advance statistic tools to analyze the data collected in a manufacturing process.
The phases are :
Phase
|
Purpose
|
Common
tools used
|
1.
Define
|
Identify
and understand the problem, establish problem statement. Define SMART goal
|
Scope
the project
COPIS/SIPOC,
process
flow
|
2.
Measure
|
Identify
what parameter to measure, collect current state data to understand what is
the performance of the key parameter
(Y). Calculate cost of quality
|
Critical
to quality
Gage
Repeatability and reproducibility
GR&R
study
Statistical
control chart
Understand
data distribution
Process
capability study
|
3.
Analyze
|
Understand
what the root cause that is contributing to the problem, root cause
analysis, what are the X
|
Fish
bone diagram
Fault
tree analysis
5
whys
X
and Y correlation
Design
of experiment to identify and quantified process input (root cause)
which contribute to Y
|
4.
Improve
|
Establish
improvement plan to address multiple process input x which contributes to poor performance in Y. Pilot run the action plan and track if
there is any significant improvement
|
PFMEA
Brainstorming tools
Error
proofing
Design
of experiment to optimize Y through control for X
Anova
analysis
|
5.
Control
|
Standardized
and sustain
After
improvement action. Document action plan in work instruction and ensure all
follow the same work instruction -
Standardization Track the performance of Y output for a time line to
if the improvement is sustainable, Calculate cost savings
|
After
improvement control chart
After
process capability analysis
Cost
benefit calculation
|
6.
Report (optional)
|
Report
phase 1-5 to management
Lesson
learned and look for next project
|
Based on the input and output diagram, process input is termed as X and process
output performance is termed as Y per below :-
In six sigma approach, we will need to understand what is the process output, Y which we would like to improve. We will need to collect data to understand which specific process input x have an effect on Y using various statistical tools. Once we have identified process input x which has an impact on Y, we can create action plan to optimize and control x. For example if we would like to improve yield
rate for a product, yield rate is Y, and process input which influence yield rate is x. After we have optimize process input X, then we will need to control X and monitor Y performance.
There are 2 types of process output data (Y) being collected
in a process :-
- Attribute data (discrete data)
- Variable data (continuous data)
Data
|
Attribute
|
Variable
|
Also
known as
|
Discrete
|
Continuous
|
Characteristics
|
Cannot
be divided have decimal point , whole
round number
Clear
operational definition of
Go,
no go,
reject,
accept
pass,
fail
|
Generated
from a calibrated measuring device and can be divided infinitely
Distance,
Length, weight
|
Method
|
Counting
of good and defect parts after going thru inspection such as visual or using
go no go jig
|
Measure
using measurement device
|
Example
|
Yield
rate
Defect
rate
Count
of reject
|
Dimension
Length, width thickness, strength,
weight etc
|
The two types of data have very different traits and use
different statistical model use to analyze. During the define and
measurement phase we must understand
what type of process output data we will be using for the six sigma
project. The table below shows the
different statistic models which are used the 2 types of data in various six sigma
phase.
Phase
|
Statistical
analysis
|
Attribute
Data
|
Variable
Data
|
Measure
|
G
R&R
|
Attribute
GR&R
|
Variable
GR&R
|
Measure
Improve
|
Statistical
control charts
|
P
chart
nP
chart
U
chart
C
chart
|
X
bar R chart
X
mR chart
X
bar sigma chart
|
Measure
Improve
|
Process
performance index
|
DMPO
|
Process
capability study
|
Measure
|
Distribution
|
Binomial
Poisson
|
Normal
|
Analyze
Improve
|
Design
of Experiment
|
Binary
logistic regression
|
Simple/Multiple
Regression
|
Improve
|
Comparative
methods
|
ANOVA
methods
T
test or Z test
|
Categorical
analysis
Chi
Square
|
Attribute data is a count data, therefore a bigger sample size is needed for all the statistical analysis above compare to variable data. In six sigma, variable data is prefer and it always encourage to find a variable metrics from attribute data. An example would be printed circuit board assembly PCBA in circuit test (ICT) which test several electrical metrics at the same time, it would be more beneficial if we can study selected variable electrical metrics rather than just the yield rate of ICT.
In real life, sometimes it is not possible to study every
parts that had been produce especially in high volume manufacturing
environment, hence we will need to use
statistical analysis of sample to made
conclusion on entire population of the part produce through 6 sigma approach. We must maintain the rigour of data
collection and statistical analysis to make a correct conclusion on the
improvement made if it is effective to achieve consistent good quality product
at optimum level.
To learn with case study to help you understand how to apply six to improve quality, click on the image or the link below👇:-