3 - qsm 754 course powerpoint slides v8
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Ground Fruit
Ground Fruit
Logic and Intuition
Low Hanging Fruit
Low Hanging Fruit
Seven Basic Tools
Bulk of Fruit
Bulk of Fruit
Process Characterization
and Optimization
Process Entitlement
Sweet Fruit
Sweet Fruit
Design for Manufacturability
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VALUE
STREAM TO
THE
CUSTOMER
PROCESSES WHICH
PROVIDE PRODUCT VALUE
IN THE CUSTOMER’S EYES
•
FEATURES OR
CHARACTERISTICS THE
CUSTOMER WOULD PAY
FOR….
WASTE DUE TO
INCAPABLE
PROCESSES
WASTE SCATTERED THROUGHOUT
THE VALUE STREAM
•
EXCESS INVENTORY
•
REWORK
•
WAIT TIME
•
EXCESS HANDLING
•
EXCESS TRAVEL DISTANCES
•
TEST AND INSPECTION
Waste is a significant cost driver and has a major
impact on the bottom line
Waste is a significant cost driver and has a major
impact on the bottom line
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Y = f(x)
All critical characteristics (Y)
are driven by factors (x) which
are “upstream” from the
results….
Attempting to manage results
(Y) only causes increased
costs due to rework, test and
inspection…
Understanding and controlling
the causative factors (x) is the
real key to high quality at low
cost
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The necessity of training farm hands for first class
farms in the fatherly handling of farm livestock is
foremost in the minds of farm owners. Since the
forefathers of the farm owners trained the farm hands
for first class farms in the fatherly handling of farm
livestock, the farm owners feel they should carry on
with the family tradition of training farm hands of first
class farms in the fatherly handling of farm livestock
because they believe it is the basis of good
fundamental farm management.
How many f’s can you identify in 1 minute of inspection….
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The necessity of* training f*arm hands f*or f*irst class
f*arms in the f*atherly handling of* f*arm livestock is
f*oremost in the minds of* f*arm owners. Since the
f*oref*athers of* the f*arm owners trained the f*arm
hands f*or f*irst class f*arms in the f*atherly handling
of* f*arm livestock, the f*arm owners f*eel they should
carry on with the f*amily tradition of* training f*arm
hands of* f*irst class f*arms in the f*atherly handling
of* f*arm livestock because they believe it is the basis
of* good f*undamental f*arm management.
How many f’s can you identify in 1 minute of inspection….36 total are available.
.
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Focus on Prevention Focus on Firefighting
Low cost/high throughput High cost/low throughput
Poka Yoke Control Strategies Reliance on Test and Inspection
Stable/Predictable Processes Processes based on Random Probability
Proactive Reactive
Low Failure Rates High Failure Rates
Focus on Long Term Focus on Short Term
Efficient Wasteful
Manage by Metrics and Analysis Manage by “Seat of the pants”
Six Sigma
Six Sigma
Traditional
Traditional
“SIX SIGMA TAKES US FROM FIXING PRODUCTS SO THEY ARE EXCELLENT,
TO FIXING PROCESSES SO THEY PRODUCE EXCELLENT PRODUCTS”
Dr. George Sarney, President, Siebe Control Systems
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Breakthrough
Strategy
Characterization
Phase 1:
Measurement
Phase 2:
Analysis
Optimization
Phase 3:
Improvement
Phase 4:
Control
•
Define the problem and
verify the primary and
secondary measurement
systems.
•
Identify the few factors
which are directly
influencing the problem.
•
Determine values for the
few contributing factors
which resolve the
problem.
•
Determine long term
control measures which
will ensure that the
contributing factors
remain controlled.
Objective
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•
If we can’t accurately measure
something, we really don’t know much
about it.
•
If we don’t know much about it, we
can’t control it.
•
If we can’t control it, we are at the
mercy of chance.
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IF WE DON’T HAVE DATA, WE DON’T KNOW
IF WE DON’T KNOW, WE CAN NOT ACT
IF WE CAN NOT ACT, THE RISK IS HIGH
IF WE DO KNOW AND ACT, THE RISK IS MANAGED
IF WE DO KNOW AND DO NOT ACT, WE DESERVE THE LOSS.
DR. Mikel J. Harry
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Random Chance or Certainty….
Which would you choose….?
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HIRING NEEDS
BEADS ARE OUR BUSINESS
BEADS ARE OUR BUSINESS
PRODUCTION SUPERVISOR
4 PRODUCTION WORKERS
2 INSPECTORS
1 INSPECTION SUPERVISOR
1 TALLY KEEPER
