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Quality Basic Tools
Aditya
Understanding the SIX SIGMA
HOW to maintain QPE elements?
Define the target (quality planning) Call for QUALITY Inspection (quality control) Redesign (quality improvement)
Quality Control strategy
Approaching to SIX SIGMA term strategy
Quality Improvement strategy
Take the FMEA (Failures Modes and Effect Analysis)
WHAT is the Purpose?
WHAT is this about?
Introduction to Six Sigma
WHAT?
A SYMBOL…
WHY?
To show the industry PERFORMANCEs (quality)
Introduction to Six Sigma
HOW?
By defining the DPMO (Defects Per Million Opportunity)
WHEN?
NOW!
Introduction to Six Sigma
WHY?
TO MAKE BETTER WORLD
Approaching Six Sigma strategy
understanding
Approaching Six Sigma strategy
Define the CTQ’s (Critical To Quality)
How many CTQ will be applied to the products ?
Approaching Six Sigma strategy
Define the total of product (TP) in a period
How many product has been manufactured?
Approaching Six Sigma strategy
Define the DPMO (defects per million opportunities)
On 1000.000 products how many defects?
Approaching Six Sigma strategy
Convert it to SIX SIGMA conversion table
Yield (success rate) ?
Sigma term (long or short)?
Six Sigma conversion table
Approaching Six Sigma strategy
Let :
Total product manufactured be Tp
Total Critical to Quality be n
Critical to quality be i
Defects total be d
Defects per group be di THEN the DPMO is
DPMO =
Σdi i=1
n
Tp x n X 1000.000
Approaching Six Sigma strategy
IBM computer manufacturing produces 54.998 IBM 5100 at the beginning of 1975. The CTQ define as 2 groups of requirements which is speed must be more than 975 Mhz, and the CPU unit must not be more than 24 C when operating. Group speed defects 8900, and temperature group defects 8876. define the DPMO.
DPMO = Σdi i=1
n
Tp x n X 1000.000
Approaching Six Sigma strategy
Let:
Total product manufactured be Tp = 54.998
Total Critical to Quality be n = 2 groups of requirements
Critical to quality be i = speed and temperature
Defects total be d = d1+d2
Defects per group be d1= 8900 , and d2=8876
DPMO = x 1000.000 8900 + 8876
54998 x 2
Approaching Six Sigma strategy
DPMO = 161.605
Six Sigma conversion table
Converting to sigma term from 161.605 Take the upper limit Inspect the SIGMA term (long or short)
Approaching Six Sigma strategy
The six sigma term = 2.40
Success rate = 81.6 %
Quality Improvement Strategy
For Production Plan up to 1000.000 products next period
Assumption of defects OP per unit= 1-(success rate/100) = 0.184
Assumption of defects OP per period = 0.184 x 1000.000 = 184.000
Assumption of success OP per period = 0.816 x 1000.000 = 816.000
Success rate = 81.6 %
Sigma term = 2.40
Next plan : upgrading to sigma 2.50!
Six Sigma conversion table
Approaching Six Sigma strategy
The six sigma term = 2.50
Success rate = 84.1 %
DPMO = 158.655
Gap = DPM(currnt)-DPM(2.50)
= 161.605 – 158.655
= 2950 defects
Approaching Six Sigma strategy
Gap percentage = (2950 / DPMO trget)
= (2950 / 158.655)
= (1.859%)
Quality Improvements Strategy
We get :
Total product manufactured be Tp = 1000.000
Total Critical to Quality be n = 2 groups of requirements
Critical to quality be i = speed and temperature
Defects total be d = d1+d2
Defects per group be d1= X1 , and d2=X2
DPMO =
158.655 = x 1000.000 X1 + X2
1000.000 x 2
Approaching Six Sigma strategy
Total unit = 1000.000 units
Defects limit = 317.310 units
Intensive inspection = 1.859 % x 1000.000
= per 18.590 units
Intensive inspection method
Introduction to FMEA (Failures Modes and Effect Analysis)
Intensive inspection regarding the defects after (n) units To overcome the cases and compare the next inspection for (2n) units Quality inspection ROUTINES - Check the list of inspection (based on the CTQ) - Inspect the procedure of most occurs defects product ex: prod line/treatment - Do Research and Development to try other method
Intensive inspection method
The product is NON conformity Why? (1)
The CPU is hot over the limit Why? (2)
The heat sink is not attached perfectly Why? (3)
The shock cause it loose Why? (4)
The screw is not tight enough Why? (5)
NEED loctite for it
Question?
Introduction to FMEA (Failures Modes and Effect Analysis)
Quiz?
Introduction to FMEA (Failures Modes and Effect Analysis)
A SPARK timetravel machine industry produces 263 timetravel (TT)
machines. They consider the microsingularities supply must not be higher
than 9 Giga joules and the jump speed must not be less than 10yrs/hr to
make the TT machines effective. After the end of the period, SPARK found
34 of their machines are considered as defects. Define what SIX SIGMA
term they are in. and if the SPARK would like to produce 6578 machines in
the next period, what is their defect limit? and per how many machines they
must do the intensive inspection ?
