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Sem 3

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Uploaded by

Madhavan K
Copyright
© © All Rights Reserved
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Principles and Key Components of Six Sigma

Principles of Six Sigma


1. Customer Focus:
o The primary aim is to understand and meet customer requirements, ensuring
satisfaction.
o All processes are aligned to deliver maximum value to the customer.
2. Data-Driven Approach:
o Decisions are based on data and statistical analysis rather than assumptions.
o Continuous data collection and measurement help identify issues and track
improvements.
3. Process Improvement:
o Emphasis on reducing process variation and eliminating defects.
o Optimizing processes to enhance efficiency and effectiveness.
4. Proactive Management:
o Identifying and addressing potential issues before they become significant
problems.
o Managers play an active role in ensuring process alignment with
organizational goals.
5. Collaboration and Teamwork:
o Success depends on cross-functional teams working together to solve
problems.
o Encourages communication and shared responsibility.
6. Continuous Improvement:
o Iterative approach to refining processes, even after achieving initial goals.
o Promotes a culture of excellence.

Key Components of Six Sigma


1. DMAIC Framework:
o Define: Identify the problem, customer needs, and project objectives.
o Measure: Collect data to understand current performance.
o Analyze: Identify root causes of defects or inefficiencies.
o Improve: Develop and implement solutions to address root causes.
o Control: Establish controls to sustain improvements.
2. Roles and Responsibilities:
o Champion: Senior leader driving Six Sigma initiatives.
o Master Black Belt: Expert in Six Sigma methodologies; mentors teams.
o Black Belt: Leads specific improvement projects and trains team members.
o Green Belt: Works on projects under the guidance of a Black Belt.
o Yellow Belt: Supports projects with basic Six Sigma knowledge.
3. Statistical Tools:
o Tools like Pareto charts, cause-and-effect diagrams, control charts, and
hypothesis testing are used to analyze data.
4. Critical to Quality (CTQ):
o Metrics that are crucial to meeting customer expectations and business goals.
5. Reduction of Variation:
o Focus on minimizing variability in processes to achieve predictable and
consistent outcomes.
6. Cost Reduction and Efficiency:
o Eliminating waste and defects to lower costs and improve productivity.

Contribution to Quality Improvement


1. Reduction in Defects:
o Six Sigma aims for near-perfect processes (3.4 defects per million
opportunities), ensuring high-quality output.
2. Enhanced Customer Satisfaction:
o By focusing on customer requirements, organizations deliver superior value,
building loyalty and trust.
3. Improved Process Efficiency:
o Streamlined workflows lead to reduced cycle times and resource utilization,
increasing overall efficiency.
4. Data-Driven Decisions:
o Organizations make informed choices using statistical insights, leading to
better results and reduced risk.
5. Employee Engagement:
o Cross-functional teams and a focus on quality empower employees, fostering
innovation and collaboration.
6. Cost Savings:
o Reduction of waste, rework, and defects translates to significant financial
benefits.
7. Sustainable Competitive Advantage:
o Continuous improvement ensures that the organization stays ahead in terms of
quality and efficiency, giving it a competitive edge.

Explain the concept of Quality Function Deployment (QFD) and its role in translating
customer requirements into product design and development. Provide a step-by-step
explanation of how QFD is implemented.

Quality function deployment (QFD) is a method to transform qualitative user demands into
quantitative parameters, to deploy the functions forming quality, and to deploy methods for
achieving the design quality into subsystems and component parts, and ultimately to specific
elements of the manufacturing process.
A QFD Tool – House Of Quality (HOQ) :
House of Quality or HOQ is conceptual map or matrix that provides an understanding of how
customer requirements (WHATs) are related to various technical descriptors or design
parameters (HOWs) and their priority levels. House of Quality is also known as Quality
Matrix. The matrix gets its name from fact that it represents the shape of house.
A House of Quality has the following parts :
1. WHATs –
Customer requirements and needs are listed.
2. Importance Factor –
The team rates each of customer requirements (WHATs) on scale of 1 to 5 based on
their level of importance to the customer. Here, 1 denotes lowest level and 5 denotes
highest level of importance to customer.
3. HOWs or Ceiling –
It comprises design features, technical descriptors and specifications of product
aligned with customer requirements.
4. Body –
HOWs are ranked on basis of their correlation of satisfying each of listed WHATs.
Body Ranking System used is set of symbols used to show Strong, Moderate, Weak or
No correlation between HOWs and WHATs. Also, each of symbols represents
numerical value.
5. Roof –
The roof indicates how design requirements(HOWs) are related to each other. Roof
Ranking System uses set of symbols to represent different types of interactions –
Strong Positive, Positive, None, Negative or Strong Negative.
The formula for Computing Importance Weight and Relative Importance Weight :
Importance Weight,
= Sum of (Importance Factor * Body Ranking Symbol Value)
in column
Relative Importance Weight,
= (Importance Weight/ Total Importance Weight) * 100
For example, if column in HOWs is as follows :

Importance Weight (A)


= (2 * 9 + 3 * 3 + 3 * 1)
= 18 + 9 + 3
= 30

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