Tags |
|
|
Links |
|
|
Atricle Dump - Six Sigma Tools for Process Control
A reader suggested recently that some of my articles should be submitted to Digg, an online website where readers submit and vote for newsworthy and interesting pieces. The advice was flattering, and indeed it seems that some of what is said here is by all accounts of interest to a broad spectrum of readers, but more interesting still is the process by which Digg aims to achieve objectives of newsworthiness.The website operates on the democratic principle that readers can pick and choose what submitted articles they want to read and whether they want to “digg” them, with the obvious result that those articles with the most number of “digs” receive front-page coverage
Processes, Procedures and Control
Organizations use the Six Sigma methodology, because you can't get any higher than 2 Sigma (“tribal” or basic knowledge) without putting strong processes and procedures in place. And without strong processes and procedures, you can not move toward higher quality and system optimization – toward perfection. Are you really satisfied with 67% of your product lost as waste? Are you satisfied with such high variability in your system?
Problems, Resources and Results
If needed, you can change your process to reduce or eliminate this variability or error. Six Sigma methodology tells you when to take action to solve a problem. It moves an organization to consistently meet the requirements and minimize the resources used in its management system. And it creates the desired results for which the system was designed.
A recent national market research by Guideline, Inc. one of the nation's largest providers of Market Research Expert Consulting and International Research shows that, 85 percent of consumers typically watch movies at home on the small screen. Even when it's a movie they want to see, 49 percent of respondents said they usually wait to purchase or rent the DVD.To better understand consumers' perceptions and preferences related to movies, we conducted an exclusive survey among 1,000 consumers. Furthermore, to ensure the survey addressed all the current issues facing the movie industry, Guideline worked with members of the Promotional Marketing Association's (PMA
That’s a pretty lofty concept. It’s definitely not easy – especially when speaking of core business processes. Moving toward perfection requires measurement, analysis and documentation. And if you really want perfection, then you need more sophisticated tools. But is driving toward that ideal of perfection worth the effort?
If you want to increase quality and dramatically save costs in production, then, yes, the road to perfection is definitely worth the driving time.
Forward Steps, Quality and Processes
Last time, we discussed process mapping to increase communication and understanding within an organization and to effectively develop a system of procedures. Now, let’s take a forward step, and look at how Six Sigma tools can decrease variability and increase quality in your processes.
Six Sigma, Pyramids and Systems
The Six Sigma methodology is an advanced set of tools designed for problem-solving and quality improvement. A 'sigma' refers to the standard deviation from the mean of a population. Standard deviation indicates the likelihood that your next data point will deviate from the mean of the data set.
At the bottom of the Six Sigma pyramid begins a system’s current process capability. Usually at 1 or 2 Sigma levels is “tribal” knowledge based on first-time experiences. An organization moves up the pyramid to 3 Sigma as systems are put in place. To hit 4 Sigma, statistics and modeling tools are used for significant process improvement. And, finally, to aim for that near perfection, organizations apply DFSS, or Design for Six Sigma.
Why?
Measurement, Analysis and Documentation
Why do (and should) organizations use these concepts to move up the pyramid and toward quality improvement? Why is it necessary to measure, analyze and document processes – and, if needed, make those desired changes? Why drive toward perfection, and what does it mean in real terms?
If your current process capability runs at 1 Sigma, then that effectively means you have two defects (unusable products) out of every 3 parts. That means 67% of your costs simply become waste, with no return on your investment. At 2 Sigma, quality improves with 1 out of 3 parts as defects. But that still has an error rate of 33%. Not until 3 and then 4 Sigma levels will you see dramatic improvements. Put in these terms, you quickly see how such errors keep you from realizing a greater potential.
Transactions, Multiple Steps and Tolerance
Organizations most effectively utilize Six Sigma methodology in two situations. One, if a business works with a very high volume of transactions per year, then they can not tolerate low sigma levels. For example, a 99% effective rate for 1 billion transactions per year still yields 10 million defects. In any industry, that is not acceptable.
Another situation that calls for Six Sigma methodology is when an organization (i.e. manufacturing) has processes with multiple steps. Here total error rate is critical. For example, the effective rate is 99% for each step; however, that does NOT give the total error rate as 1%. You must take the 99% for the first step and multiply it by 99% for the second step, the third step, and so on. With a great number of steps, your total effective rate could significantly decrease. So, to avoid high volatility, this organization can not tolerate low sigma levels.
Organizations can also determine error rate by effectively reversing the typical process of Six Sigma. You can calculate the mean and variance in your process to define the error rate. This tells you where you are currently on the Six Sigma curve. For example, if your calculation tells you that you're on a 1 or 2 sigma level, then this is an area in need of improvement. This gives you an opportunity to look at the data more carefully, take the mean and variance of each step of the process, and determine in which step the process is having problems. Or it could tell if you there are many steps causing the problems and, thus, the cumulative increase in error rate.
Processes, Procedures and Control
Organizations use the Six Sigma methodology, because you can't get any higher than 2 Sigma (“tribal” or basic knowledge) without putting strong processes and procedures in place. And without strong processes and procedures, you can not move toward higher quality and system optimization – toward perfection. Are you really satisfied with 67% of your product lost as waste? Are you satisfied with such high variability in your system?
Problems, Resources and Results
If needed, you can change your process to reduce or eliminate this variability or error. Six Sigma methodology tells you when to take action to solve a problem. It moves an organization to consistently meet the requirements and minimize the resources used in its management system. And it creates the desired results for which the system was designed.
Creating an internal MRO virtual warehouse (or Corporate MRO Catalog) allows a multi-site corporation to leverage its assets across the entire organization and deliver value for inventory parts.With a Corporate Catalog, a company is able to have a single view of all corporate data. Consolidating parts across the company into a “virtual” warehouse becomes a powerful tool for the organization. Total inventory can be viewed to determine volume usage, part equivalences, common suppliers, price variations, etc.To further increase volume purchases and reduce pricing, product lines can be selected and mandated, the supplier base can be consolidated, and Preferred Susigma' refers to the standard deviation from the mean of a population. Standard deviation indicates the likelihood that your next data point will deviate from the mean of the data set.
At the bottom of the Six Sigma pyramid begins a system’s current process capability. Usually at 1 or 2 Sigma levels is “tribal” knowledge based on first-time experiences. An organization moves up the pyramid to 3 Sigma as systems are put in place. To hit 4 Sigma, statistics and modeling tools are used for significant process improvement. And, finally, to aim for that near perfection, organizations apply DFSS, or Design for Six Sigma.
Why?
Measurement, Analysis and Documentation
Why do (and should) organizations use these concepts to move up the pyramid and toward quality improvement? Why is it necessary to measure, analyze and document processes – and, if needed, make those desired changes? Why drive toward perfection, and what does it mean in real terms?
If your current process capability runs at 1 Sigma, then that effectively means you have two defects (unusable products) out of every 3 parts. That means 67% of your costs simply become waste, with no return on your investment. At 2 Sigma, quality improves with 1 out of 3 parts as defects. But that still has an error rate of 33%. Not until 3 and then 4 Sigma levels will you see dramatic improvements. Put in these terms, you quickly see how such errors keep you from realizing a greater potential.
Transactions, Multiple Steps and Tolerance
Organizations most effectively utilize Six Sigma methodology in two situations. One, if a business works with a very high volume of transactions per year, then they can not tolerate low sigma levels. For example, a 99% effective rate for 1 billion transactions per year still yields 10 million defects. In any industry, that is not acceptable.
Another situation that calls for Six Sigma methodology is when an organization (i.e. manufacturing) has processes with multiple steps. Here total error rate is critical. For example, the effective rate is 99% for each step; however, that does NOT give the total error rate as 1%. You must take the 99% for the first step and multiply it by 99% for the second step, the third step, and so on. With a great number of steps, your total effective rate could significantly decrease. So, to avoid high volatility, this organization can not tolerate low sigma levels.
Organizations can also determine error rate by effectively reversing the typical process of Six Sigma. You can calculate the mean and variance in your process to define the error rate. This tells you where you are currently on the Six Sigma curve. For example, if your calculation tells you that you're on a 1 or 2 sigma level, then this is an area in need of improvement. This gives you an opportunity to look at the data more carefully, take the mean and variance of each step of the process, and determine in which step the process is having problems. Or it could tell if you there are many steps causing the problems and, thus, the cumulative increase in error rate.
Processes, Procedures and Control
Organizations use the Six Sigma methodology, because you can't get any higher than 2 Sigma (“tribal” or basic knowledge) without putting strong processes and procedures in place. And without strong processes and procedures, you can not move toward higher quality and system optimization – toward perfection. Are you really satisfied with 67% of your product lost as waste? Are you satisfied with such high variability in your system?
Problems, Resources and Results
If needed, you can change your process to reduce or eliminate this variability or error. Six Sigma methodology tells you when to take action to solve a problem. It moves an organization to consistently meet the requirements and minimize the resources used in its management system. And it creates the desired results for which the system was designed.
Several companies specialize in providing packaging services that are sourced by manufacturers to deliver well packaged products to their consumers. The existence and usage of highly sophisticated packaging equipment for different kinds of products has made good quality packaging a must for all products that reach retail shelves.Large scale manufacturers find it more cost effective to include a sophisticated packaging machine in the assembly line and turn out a packaged product ready to be shipped. However, for smaller manufacturers, investing in a packaging machine is not a viable option. So they opt for packaging services offered by specialists to give their producs capability runs at 1 Sigma, then that effectively means you have two defects (unusable products) out of every 3 parts. That means 67% of your costs simply become waste, with no return on your investment. At 2 Sigma, quality improves with 1 out of 3 parts as defects. But that still has an error rate of 33%. Not until 3 and then 4 Sigma levels will you see dramatic improvements. Put in these terms, you quickly see how such errors keep you from realizing a greater potential.
Transactions, Multiple Steps and Tolerance
Organizations most effectively utilize Six Sigma methodology in two situations. One, if a business works with a very high volume of transactions per year, then they can not tolerate low sigma levels. For example, a 99% effective rate for 1 billion transactions per year still yields 10 million defects. In any industry, that is not acceptable.
Another situation that calls for Six Sigma methodology is when an organization (i.e. manufacturing) has processes with multiple steps. Here total error rate is critical. For example, the effective rate is 99% for each step; however, that does NOT give the total error rate as 1%. You must take the 99% for the first step and multiply it by 99% for the second step, the third step, and so on. With a great number of steps, your total effective rate could significantly decrease. So, to avoid high volatility, this organization can not tolerate low sigma levels.
Organizations can also determine error rate by effectively reversing the typical process of Six Sigma. You can calculate the mean and variance in your process to define the error rate. This tells you where you are currently on the Six Sigma curve. For example, if your calculation tells you that you're on a 1 or 2 sigma level, then this is an area in need of improvement. This gives you an opportunity to look at the data more carefully, take the mean and variance of each step of the process, and determine in which step the process is having problems. Or it could tell if you there are many steps causing the problems and, thus, the cumulative increase in error rate.
Processes, Procedures and Control
Organizations use the Six Sigma methodology, because you can't get any higher than 2 Sigma (“tribal” or basic knowledge) without putting strong processes and procedures in place. And without strong processes and procedures, you can not move toward higher quality and system optimization – toward perfection. Are you really satisfied with 67% of your product lost as waste? Are you satisfied with such high variability in your system?
Problems, Resources and Results
If needed, you can change your process to reduce or eliminate this variability or error. Six Sigma methodology tells you when to take action to solve a problem. It moves an organization to consistently meet the requirements and minimize the resources used in its management system. And it creates the desired results for which the system was designed.
Question: How can I maximize the amount of cash I receive when I sell my business?Answer: Acquire every last after tax dollar and get paid in cash. Also, follow three critical steps before proceeding:1. Preplan the sale of your business. This should not be a spur of the moment decision. Rather, it should be well planned in advance. Though it is not possible to control the external environment, such as interest rates and strength of the economy, it is possible to plan for an orderly transition. Start thinking about some obvious sources for a potential buyer. For example, should an employee be groomed for possible succession? Might a good customer be interested h multiple steps. Here total error rate is critical. For example, the effective rate is 99% for each step; however, that does NOT give the total error rate as 1%. You must take the 99% for the first step and multiply it by 99% for the second step, the third step, and so on. With a great number of steps, your total effective rate could significantly decrease. So, to avoid high volatility, this organization can not tolerate low sigma levels.
Organizations can also determine error rate by effectively reversing the typical process of Six Sigma. You can calculate the mean and variance in your process to define the error rate. This tells you where you are currently on the Six Sigma curve. For example, if your calculation tells you that you're on a 1 or 2 sigma level, then this is an area in need of improvement. This gives you an opportunity to look at the data more carefully, take the mean and variance of each step of the process, and determine in which step the process is having problems. Or it could tell if you there are many steps causing the problems and, thus, the cumulative increase in error rate.
Processes, Procedures and Control
Organizations use the Six Sigma methodology, because you can't get any higher than 2 Sigma (“tribal” or basic knowledge) without putting strong processes and procedures in place. And without strong processes and procedures, you can not move toward higher quality and system optimization – toward perfection. Are you really satisfied with 67% of your product lost as waste? Are you satisfied with such high variability in your system?
Problems, Resources and Results
If needed, you can change your process to reduce or eliminate this variability or error. Six Sigma methodology tells you when to take action to solve a problem. It moves an organization to consistently meet the requirements and minimize the resources used in its management system. And it creates the desired results for which the system was designed.
Forming methods of ceramics are sometimes classified as wet or dry. Dry forming refers to pressing operations from dry or perhaps damp powders. Wet forming includes slip casting and plastic forming methods. For a review of industrial forming methods see Ceramics: Industrial Processing and Testing by John T. Jones and M. F. Berard, Iowa State University Press.Dry pressing requires that a shape be dimensionally stable after firing. That will occur if the pressing operations are in control and the firing is specified. If a pressed part is oversize after firing, it can be ground to size, but that is an extra operation usually not included in the costing of the parr it could tell if you there are many steps causing the problems and, thus, the cumulative increase in error rate.
Processes, Procedures and Control
Organizations use the Six Sigma methodology, because you can't get any higher than 2 Sigma (“tribal” or basic knowledge) without putting strong processes and procedures in place. And without strong processes and procedures, you can not move toward higher quality and system optimization – toward perfection. Are you really satisfied with 67% of your product lost as waste? Are you satisfied with such high variability in your system?
Problems, Resources and Results
If needed, you can change your process to reduce or eliminate this variability or error. Six Sigma methodology tells you when to take action to solve a problem. It moves an organization to consistently meet the requirements and minimize the resources used in its management system. And it creates the desired results for which the system was designed.
Systems, Control and Perfection
Remember, though, you can only get to 3 or 4 sigma by developing a system of policies and procedures of measurement, analysis and documentation. And with this you will easily see that reducing your error rate and moving toward perfection with Six Sigma tools is well worth the driving time – and, more, crucial to your system’s control.
HTTP = HTML link (for blogs, profiles,phorums):
<a href="http://www.articledump.net/article/4992/articledump-Six-Sigma-Tools-for-Process-Control.html">Six Sigma Tools for Process Control</a>
BB link (for phorums):
[url=http://www.articledump.net/article/4992/articledump-Six-Sigma-Tools-for-Process-Control.html]Six Sigma Tools for Process Control[/url]
Related Articles:
The Impact of Oil Prices on the Freight Industry
The Benefits Of Being Able To Print Postage At Home
Bookmark it:
|