April 2005

Slide 1

6 Sigma

6

Plastics NZ : Best Practice Seminar 2005

April 2005

Slide 2

Why sigma? Why 6?

Examples

DMAIC - the method of 6

Training

Deployment

Pitfalls

Session Topics

April 2005

Slide 3

Industries that have influenced me...

April 2005

Slide 4

Examples where I’ve seen much value added:

Waste minimisation:

- water, fuel, oil, compressed air

- landfill

Defects

- claims, repacks

Design

- technical manuals

- die changing

April 2005

Slide 5

DMAIC ( ideal vs actual )

Define

Measure

Analyse

Improve

Control

April 2005

Slide 6

Define

Business case for value

Problem statement

Project goal

Metrics defined : primary & secondary

April 2005

Slide 7

“During Jan to March production averaged xx tonne/month of scrap more than the previous year at a cost of $yyM in lost sales”

“Losses due to scrap are xxx tonnes per year and $ yyyM in lost sales.”

“Reduce scrap by 1% from 3.6% to 2.6%, which will gain $yM in sales by December”

April 2005

Slide 8

defects - which codes,

- where counted and recorded

Primary metric

Secondary metrics

production rate

other defect codes

April 2005

Slide 9

Compressed air : lurking value can often help define the goal

April 2005

Slide 10

Process identified

Measurements validated

X’s : identified and prioritised

Project plan updated

MeasureWarehouseSupplier

April 2005

Slide 11

Vacuum Form

Assemble WarehouseExtrude Insp

Return for regrind / scrap

Supplier

Process map

Sampling

Measuring

Gauge r & R

April 2005

Slide 12

Analyse

Critical X’s : narrowed

Project plan updated

April 2005

Slide 13

Improve

Critical X’s : validated

Project plan updated

April 2005

Slide 14

Control

Critical X’s : hierarchy for control

Recommend how gains will be verified

Report completed

April 2005

Slide 15

Critical X’s : hierarchy for control

April 2005

Slide 16

Verify : sustaining the gains

- audit

- primary metric

April 2005

Slide 17

> 3-5 weeks in between project work

> progress tracked using

- OJT

- regular consulting sessions

- report out before next training

> verbal defence of project

Training

April 2005

Slide 18

> Belts

- Master Black Belt

- Black Belt

- Green Belt

( Yellow Belt)

- Support roles

> Time required

Deployment - who

April 2005

Slide 19

Manufacturing

Service

Design

Deployment - where

April 2005

Slide 20

> KPI and strategy

> $50K+

> enabling

> cluster

Deployment - value

April 2005

Slide 21

Pitfalls:

> no ‘end-in-mind’ - competing distractions

> don’t achieve quick success - “takes too long”

> doesn’t fit with our projects or business

> avoiding the hard to measure aspects

Further reading: Quality Progress January, 2005 pp 37-42

April 2005

Slide 22

Next Steps for Plastics

~12 objectives including...

Increase direct exports by xxx

200 technicians/year

23% recyling

material substitution, etc, etc

source Feb 2005 Newsletter

ALL REQUIRE S I X S I G M A !!!