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Using Six Sigma on a Process

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  • January 31, 2006 at 5:06 pm #42210

    shawn
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    I’m currently looking at using Six Sigma tools and methodology to help improve a process.  I’m having a hard time of coming up with measurables for this process.  Which then ?’s whether Six Sigma would be good for improving this process.  If anyone one can help me think outside of the box to define the measuables this would be greatly appreciated. 
    The process I’m working on is collecting defects in the field (Defect Reporting Process).  Currently we have 5 – 7 different databases that collect failed parts (defects) in the field.  They all talk differently and some customer’s there is no reporting process at all.
    To have Six Sigma help, I need measurables that show variances in the process.  I think the key is to have one database but ,I want Six Sigma to tell me this.  Can anyone help?
    Thanks
    Shawn

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    January 31, 2006 at 5:18 pm #133143

    JettSetter
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    Hi Shawn…
    My first reaction is….why arent you going after the process that is producing these defects……you wouldnt be needing that database if you dealt with the root causes of those defects. 
    Secondly…it doesnt sound like you are truly going through the DMAIC process and using some the tools available….doesnt sound like you have ID’d the output unit, specs, fishboned it …etc…..
    Thirdly…you may be dealing with 5-7 different processes all together.  Maybe standardize the process….clearly define the defects to be reported….and then proceed….
     

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    January 31, 2006 at 5:36 pm #133148

    shawn
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    The product we make is rather large and has hundreds of parts in it. Failures occur daily and each failure is usually a different part.   So there is wide vareity of components.  This is why the collection of the failed parts is important to establish trends, etc.   This process to collect these failures varies within six + different databases. 
    I have SIPOC defined, I’m just having a hard time trying to show either a control chart or histogram  on varation of a process.    I understand how Six Sigma can be used to control variation on a  upper and lower limits on parts but not on a process.  It is just harder when your part is the process and knowing what your varation is. 

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    January 31, 2006 at 5:41 pm #133150

    Mr IAM
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    So…. in a perfect world (i.e… six sigma) there would be no part failures? Correct?
    So any part failure is a defect – right?  So, now the question in is… What is your Unit? or your Opportunity for failure?  Is it each machine?  Probably so…
    You need to define your “defect” your “unit” your “opportunity” then you can measure your Sigma, and do a Control Chart.  But the point should be to indentify your Measurable Y upfront.  What are you trying to fix????

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    January 31, 2006 at 6:31 pm #133156

    JettSetter
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    Lam hit it on the head…..
    Sounds like you have a unit with many defect opportunities running through a process.  And off the top it sounds like you want to pareto your defects types….?

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    January 31, 2006 at 7:00 pm #133158

    Mr IAM
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    That is good thought.  You could focus the project on the part that is failed most offen by using a Pareto Chart.  Keep it simple.

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