Modul 1.1: Introduction & Basics
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This document provides an introduction to Lean Six Sigma White Belt training. It defines Six Sigma as a strategy for improving quality and cutting costs through a methodology using statistical tools. The goals are to achieve near-zero defect levels by striving for 6 standard deviations between the mean and nearest specification limit. Examples show the cost savings that can be achieved by reducing the number of defects from 3.4 sigma to 6 sigma levels. A brief history of Six Sigma outlines how various companies implemented it from the 1980s onward.
Modul 1.1: Introduction & Basics
- 1. Lean Six Sigma White Belt Training Modul 1.1: Introduction & Basics https://leanbase.de/onlineacademy
- 2. Lean Six Sigma White Belt Training — 1.1 Introduction & Basics What is Six Sigma?
- 3. Lean Six Sigma White Belt Training — 1.1 Introduction & Basics A greek letter?
- 4. Lean Six Sigma White Belt Training — 1.1 Introduction & Basics A mathematical / statistical term for standard deviation? And a torture for students?
- 5. Lean Six Sigma White Belt Training — 1.1 Introduction & Basics An improvement methology?
- 6. Lean Six Sigma White Belt Training — 1.1 Introduction & Basics σ = i=1 N (Xi−µ)2 N A I CD M
- 7. Lean Six Sigma White Belt Training — 1.1 Introduction & Basics Again – What is Six Sigma? • A strategy for … • cutting costs, increasing quality, shortening leadtimes, boosting efficiency etc. in a very rapid manner • A methodology and a toolbox • Well proven quality tools packed in effective project models • A common vocabulary and language • A mindset and cultural change • Reveals non-value add costs to operational leaders and brings “a sense of urgency” culture to the organization • A non-firefighting approach that is focusing on critical business areas.
- 8. Lean Six Sigma White Belt Training — 1.1 Introduction & Basics Why Six Sigma? Or: Is 99 % (3.8σ) not good enough?
- 9. Lean Six Sigma White Belt Training — 1.1 Introduction & Basics Examples for 𝟗𝟗 % = 𝟑. 𝟖𝛔 In reality Sigma level 12 Incidents each day at starts or landings on FRA 10,000 counterfeit notes in 1 million notes 7.2 h per month w/out power supply in a household 700,000 lost letters each day 20,000 lost packets each day 1,000 prisoners per 100,000 citizens 241 lost driving licences during Oktoberfest 1 delayed train per 100 315,000 lost heartbeats per person Numbers from 2010
- 10. Lean Six Sigma White Belt Training — 1.1 Introduction & Basics Examples for 𝟗𝟗 % = 𝟑. 𝟖𝛔 In reality Sigma level 12 Incidents each day at starts or landings on FRA – > 7 σ 10,000 counterfeit notes in 1 million notes 50 5.6 σ 7.2 h per month w/out power supply in a household 15 min 4.9 σ 700,000 lost letters each day 40,000 4.8 σ 20,000 lost packets each day 2,000 4.6 σ 1,000 prisoners per 100,000 citizens 96 4.6 σ 241 lost driving licences during Oktoberfest 517 3.5 σ 1 delayed train per 100 21.5 2.3 σ 315,000 lost heartbeats per person – – Numbers from 2010
- 11. Lean Six Sigma White Belt Training — 1.1 Introduction & Basics Cyber Monday 2013 Cost of Amazon order error @ 5𝛔 Total orders Errors Average cost per error Total cost of errors 36.8 million 8574.4 $35 $300,104.00 Cost of Amazon order error @ 6𝛔 Total orders Errors Average cost per error Total cost of errors 36.8 million 125.12 $35 $4,379.20
- 12. Lean Six Sigma White Belt Training — 1.1 Introduction & Basics Cyber Monday 2013 Sigma level Defects per million opportunities Error free percentage Resulting Cyber Monday defects Total cost (at $35 estimate per error) One Sigma 690,000.400 32.0000000 25,392,000.00 $888,720,000 Two Sigma 308,000.400 69 0000000 11,334,400.00 $396,704,000 Three Sigma 66,800.400 93.3000000 2,458,240.00 $86,038,400 Four Sigma 6,200.400 99.3800000 228,160.00 $7,985,600 Five Sigma 233.400 99.9770000 8,574.00 $300,104 Six Sigma 3.400 99.9996600 125.12 $4,379 Seven Sigma 0.019 99.9999981 < 1.00 —
- 13. Lean Six Sigma White Belt Training — 1.1 Introduction & Basics Six Sigma – a brief history • 1974: Matsushita takes over loss-making Quasar (TV manufacturer) from Motorola (150-180 defects per 100 TV) • 1979: Defects reduced to 3 per 100 TV • 1984: Initial target setting at Motorola • 10x level of improvements in service & quality by 1989 • 100x improvements by 1992 • Six Sigma capability by 1992 • 1984: Texas Instruments & ABB work closely with Motorola to further develop Six Sigma
- 14. Lean Six Sigma White Belt Training — 1.1 Introduction & Basics Six Sigma – a brief history (2) • 1988: Motorola wins 1st Malcolm Baldridge Award • 1995: Allied Signal begins Six Sigma – capturing general interest of Wall Street • 1995: General Electric (CEO Jack Welsh) began the most widespread untertaking of Six Sigma attempted, with cost savings of $7-10 billion in the first five years • Since 1997: Six Sigma spans industries worldwide
- 15. Lean Six Sigma White Belt Training — 1.1 Introduction & Basics The Y = f(x1, x2, x3, …, xn) Approach Fact based & business case driven method going from the big ‘Y‘ to tangible critical to quality Xs. Cost of Poor Quality
- 16. Lean Six Sigma White Belt Training — 1.1 Introduction & Basics Pizza = Flour + Water+ Yeast + Tomatos + Cheese 90 % 90 % 90 % 90 % 90 %
- 17. Lean Six Sigma White Belt Training — 1.1 Introduction & Basics Pizza Yield = 90 % x 90 % x 90 % x 90 % x 90 %
- 18. Lean Six Sigma White Belt Training — 1.1 Introduction & Basics Pizza Yield = 59 %
- 19. Lean Six Sigma White Belt Training — 1.1 Introduction & Basics
- 20. Lean Six Sigma White Belt Training — 1.1 Introduction & Basics ↓Yield / # op 3 10 100 1,000 10,000 80 % 51.2 % 11 % ~0 % 0 % 0 % 95 % 85.7 % 21.5 % 0.5921 % 0 % 0 % 99.99 % 99.97 % 99.9 % 99.0 % 90.48 % 36.79 % 99.9997 % 99.999 % 99.997 % 99.970 % 99.7004 % 97.0445 % Six Sigma
- 21. Lean Six Sigma White Belt Training — 1.1 Introduction & Basics A I CD M