Notes on Six Sigma Methodology in Manufacturing

Introduction to the Problem

• Company produces luxury cars.
• Production numbers declining (from 1,000 to 2,000 cars daily).
• Quality issues with windshield wipers.
• Need to identify process issues and improve production rates.

Six Sigma Overview

• Introduced in 1980 by Bill Smith at Motorola.
• Worldwide adoption to improve processes.
• Aims to reduce time, defects, and variability in processes.
• Achieves product effectiveness of 99.9996%, allowing only 3.4 errors per 1 million opportunities.
• Benefits:
  • Increases customer loyalty.
  • Improves employee morale and productivity.

Major Methodologies of Six Sigma

DMAIC

• Acronym for Define, Measure, Analyze, Improve, Control.
• Used for improving existing products/processes.

1. Define

• Identify issues, improvement opportunities, and customer requirements.
• Focus on manufacturing process issues (e.g., windshield wiper quality).

2. Measure

• Assess current process performance.
• Key metrics:
  • Daily car production (1,000 cars).
  • Time taken to assemble cars and attach wipers.
  • Defects detected from each machine.

3. Analyze

• Determine root causes of defects/variability.
• Example findings:
  • One machine’s poor performance impacted production speed.
  • Inefficient movement of car chassis due to late wheel attachment.

4. Improve

• Implement changes to the process.
• Actions taken:
  • Replace faulty machines.
  • Attach wheels earlier in the assembly line.

5. Control

• Regularly monitor and adjust processes based on changes.
• Achieved production of about 2,000 cars daily with better quality.

DMADV

• Acronym for Define, Measure, Analyze, Design, Verify.
• Used for creating new products/services from scratch (DFSS).

1. Define

• Gather customer requirements, historical data, and market research.

2. Measure

• Develop specifications based on customer requirements.
• Key specifications include top speed, engine type, and frame type.

3. Analyze

• Evaluate product performance and identify areas for improvement.

4. Design

• Create a new product based on analysis; revise designs as needed.

5. Verify

• Ensure final product meets/exceeds customer requirements.
• Gather feedback after launch to inform future designs.

Industries Utilizing Six Sigma

• Sectors include:
  • Petrochemical
  • Healthcare
  • Banking
  • Government
  • Software

Lean Methodology

• Focuses on removing non-value-added processes.
• Originated from Japanese manufacturing (Toyota).
• Emphasizes efficiency and quality.

Lean Six Sigma

• Combination of Lean and Six Sigma methodologies.
• Aims to eliminate inefficiencies and improve quality while satisfying customer needs.

Quiz

• What methodology is used to create a new product from scratch?
  • A. Define Measure Analyze Design Verify
  • B. Define Measure Analyze Improve Control
  • C. Design Measure Analyze Improve Control

Conclusion

• Importance of Six Sigma in identifying and resolving manufacturing issues.
• Continuous improvement and customer satisfaction are key objectives.