σ6 Six Sigma, it makes Better & Competitive - - 200138 : KOREA SiGMA MANAGEMENT C G
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Function Method Measurement ( / Input Input : Man / Machine Man Machine Machine Man / Measurement Man Measurement Man Output f(x s = Y Y (X: / Page 3
1.5 Shift DZ ST -Z LT A B Shift C Technology D 4 Sigma 6 Sigma Z ST Sigma Page 4
TPM ( Six Sigma (,, OEE ( CTQ (Process CTQ1 CTQ2 CTQ3 CTQ4 CTQ5 MECE Process1 Process2 Process3 ( Step 1 2 3 TFT Process4 Process Project CTQ Project OEE:Overall Equipment Efficiency Page 5 CTQ:Critical to Quality
( OEE -- 24Hr Full : OEE, ( : Lead Time,, fl TPM (OEE Manufacturing,, CTQ - Impact: - (Project Six Sigma (CTQ (R&D DFSS ( Transaction Page 6
Six SigmaTPM TPM Six Sigma Y Big Y (CTQ s :,,, y y y y y CTQ y, TFT, Trivial Many Vital Few (X s TFT x x x x x x x x x x x x Key (CTP K OREA S ig MA M ANAGEMENT C G. Page 7
Six Sigma(Mgf TPM( OEE( C/T Capa C/T Up L/T *RTY 18 20 5 Capability-Productivity 19 CTQ Key Cycle Time 10 *COPQ 7 *VA/NVA 9 21 Six Sigma :9 : 3 :1 11 11 8 6 19 19 13 9 12 TPM Transaction Six Sigma * RTY: Rolled Throughput Yield, COPQ: Cost of Poor Quality, VA: Value Added, NVA: None Value Added Page 8
6 SIGMA TPM Manufacturing Theme (90 ~00 TPM 6 Sigma (C-TLead (Speed RTY(YieldTime/ : (90 ~00, JIPM (94 ~00, (96 ~00, Six Sigma (98 ~00 Page 9
Six SigmaTPM On-Line Step TPM < Six Sigma TPM >Six Sigma, ( Scope : Process Project TPM Six Sigma Process Off-Line Modify Process Scope Company Big Y - Process Project, CTQ Project, Process CTQ Project -Impact Impact ( Resource Solution (Ownership Page 10
Six SigmaTPM Q C D Q C D Step Q C D Performance - Ownership Management TPM Optimizing Process Model - - TPM - Step - Ownership Off-Line Process - Project TPM (Tool - TPM Six Sigma (TPMSix Sigma TPM Six Sigma ( Six Sigma TPM Page 11
Six SigmaTPM TPM OEE C/T C/T Capability- Six Sigma 5 Keys Productivity Cycle Time RTY : COPQ VA/NVA Capa Up L/T Six Sigma + TPM (OEE C/T L/T RTY Transaction Project Page 12
& Solution Process (OUT-PUT Measure. SOP* Process (OUT-PUT Measure. MAP Process LAY-OUT / / / MAP( (OUT-PUT Process,, (OUT-PUT (Option Measure. ( Claim / / / (, C/E Diagram. Data Measure. Data ( /. % (10% Trouble (Sub-CTQ / Gage Process R&R ( / (Process Mapping (OUT-PUT R&R Data Study (30% Benchmarking Base-line. Benchmarker/Attribute Best Performance. Define.? Distinct Category No (4 /Mind Mapping Process Best Performance (OUT-PUT. Gage R&R Gage R&R / Analysis. ( Measure?. ( Cross Functional / / ( Data Data Analysis. Measure Gage R&R.. Data ( Gap Analysis Improve Improve..? Run Chart. : Calibration,. / OPL(Lot, (Cp=2, Cpk=1. 5 Analysis.. : Screening, OPL(One Point Lesson: PM /Why-Why AnalysisImprove. /.. / / /? (Sigma,? Check PM List, C/E Diagram, Why-Why Analysis. Improve,.. Simulation Test C&E Diagram(4M1E Risk Management *SOP: Standard Improve/ Operation Procedure. Why-Why /. CONTROL CONTROL? Logic Tree(,, (,. Multi-Vary(Data Chart Improve.., Audit System ( Chart Page 13
Process (OUT-PUT Measure. MAP LAY-OUT MAP(,, ( / / / ( C/E Diagram. Trouble / Data Base-line Analysis. Improve. ( / /. / / /., Page 14
Process (OUT-PUT Measure. Claim, (Sub-CTQ.? /Mind Mapping?.? / Run Chart Analysis.?? PM, C/E Diagram, Why-Why Improve/. CONTROL CONTROL? ( Page 15
Process (OUT-PUT Measure Analysis Improve.. Benchmarker.. Best Performance Best Performance ( Cross Functional ( ( OPL(One Point Lesson: (Process Mapping Benchmarking Gap. / Page 16
Process (OUT-PUT Measure. SOP* / / / (Option. Data. Gage R&R Data ( / Gage R&R ( / /Attribute Gage R&R / % (10% R&R Study (30% Distinct Category No (4 Analysis. Gage R&R Improve. : Calibration, :, OPL. Check List *SOP: Standard Operation Procedure Page 17
Process (OUT-PUT Measure. Data Data Data. (Lot, (Sigma, (Cp=2, Cpk=1. 5 Analysis. C&E Diagram(4M1E Why-Why Risk Management Logic Tree(,,, Multi-Vary(Data Improve.., Audit System ( Chart Page 18
Process (OUT-PUT Define. Measure. Analysis. Screening PM /Why-Why / Improve. Simulation Test. Chart Page 19
& Solution Measure Analysis Improve Process (OUT-PUT. MAP MAP Process (OUT-PUT. Measure. NECK TIME LAG TIME LAG( ( -. Base Line Process (Bath-tub (OUT-PUT,. Measure. (,, ( Analysis.,,.. / Breakthrough Idea / Improve. *, Analysis. * (. Quick-Fix (,. (Gap. Brainstorming Multi-voting 5S C/E Diagram, Why-Why.. Quick Fix( Action Plan. Improve (,,. * : * : Page 20
Process (OUT-PUT Measure. MAP MAP Analysis Improve.. TIME LAG TIME LAG( ( - (Bath-tub.. / Breakthrough Idea / Page 21
Process (OUT-PUT Measure. NECK. Base Line, ( Analysis.,,,, ( Improve.. (Gap 5S.. Page 22
Process (OUT-PUT Measure.. *, Analysis.. * Quick-Fix (, Brainstorming C/E Diagram, Why-Why ( Multi-voting Improve. Quick Fix( (,, Action Plan. * : * : Page 23
& Solution Cycle Time Lead Time RTY(Yield Process (OUT-PUT Measure. Base Line Target LOB(Line Of Balance / C/T Pareto Process (M/T,. (Sigma (OUT-PUT, C/T (Sub-CTQ Measure. Lay Out Process Process Mapping (Logical Tree Process Map Diagram ( (OUT-PUT Process / ( Define. RTY CTQ Data,, Tool RTY ( Loss ( (Part, Consensus Analysis. Measure. RTY Process Mapping/ C/E Diagram/ Process Mapping C/E Diagram. Brainstorming/ Why-Why Data Hidden (, Loss,. vs C/E Matrix Improve. Table VA./NA RTY Screening DOE Neck. Review ( sigma C/T GAP List Tool,, Base-line., (vs Analysis Analysis., Skill Loss, Logic Loss Tree, ; Logic (Loss Tree / C/E Diagram. C/E Diagram System Chart : System Improve Why- Why. Loss, Tool Skill, Improve. List Visual Management.., 3 Setting, SOP,, (Fan out Page 24
Cycle Time Process (OUT-PUT Measure Analysis Improve. Base Line Target.. LOB(Line Of Balance / C/T Pareto (M/T,. (Sigma, C/T (Sub-CTQ (Logical Tree CTQ Data (Part, Process Mapping/ C/E Diagram/ Brainstorming/ Why-Why Table Screening DOE ( Tool,,, (vs, C/E Diagram vs C/E Matrix C/T List. Chart Page 25
Lead Time Process (OUT-PUT Measure. Lay Out Process Mapping Process / (,, Tool Process Map Diagram (. Data (,,. VA./NA Neck sigma Analysis. Logic Tree C/E Diagram Why- Why Logic Tree C/E Diagram Improve.., 3 Visual Management Page 26
RTY(Yield Process (OUT-PUT Define Measure. RTY. RTY RTY ( Consensus Process Mapping Hidden Loss RTY Loss (. Review GAP Base-line Analysis Improve.. Loss, Skill Loss, ; Loss (Loss / System :, Tool Skill, System. Setting, SOP,, (Fan out List Page 27
Y NA = Normalized Yield Opp = ( Y NA Process. Y NA ProcessZ(. Y NA Process
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World Best Practice!,, Engineer Skill Up T P M Line Ownership Six Six Sigma + TPM Mind CTQ Six Sigma ( Fundamental Process Loss Knowledge Sharing Page 34