WHAT IS SIX SIGMA?

DEFEAT THE COMPETITION BY UNDERSTANDING AND THEN EXCEEDING CUSTOMERS EXPECTATION SET STRETCHED GOALS CONSTANTLY MEASURE TO DEFECT IMPROVEMENT DELIVERY PRICE QUALITY--

CYCLE TIME- SIMPLIFY THE PROCESS COST - REDUCING COST THRO EFFICIENCY ENHANCEMENT DEFECTS- ELIMINATE VARIATION

Sigma processes at a glance

LSL USL

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TAGUCHIS LOSS FUNCTION

Other expression of Six Sigma ?

A measure of variation that achieves 3.4

defects per million opportunities

A measurement system of performance A goal

Effect of variation
Supplier Input Process Output Customer

Variation in input

Variation in process

Variation in output

Defects

Six sigma projects can be applied-

To reduce cycle time- To crash critical time by eliminating non value added

processes/ steps( overhauling time reduction, to reduce bar to bar outage of the units)

To reduce cost of manufacturing- By optimization of critical inputs say spares

chemicals, consumables etc.

To reduce/ eliminate waste - By increasing HEAT- RATE of the units,

by decreasing APC of the units, to avail opportunity to maximize our UI and so on

Whats important to the customer? Whats important to the business/strategy What are the expectations Management direction CTXs Voice of the customer Historical data

What historical data is available? What is benchmark performance? What is the long & short term capability? What are the Xs and Ys

Define
QFD/House of Quality Customer surveys Is/is not analysis Process map Thought process map

Black Belt project/ problem statement

Measure
Process map Thought process map Measurement System Evaluation Control Charts Capability DPU/RTY Mean Distribution

What is between/within? What data is available/practical? Is data variable or attribute? Information for product/process change

Analyze
Normal plots Histogram Fishbone Pareto Scatter plot SPC/control charts Rational subgrouping Hypothesis testing

Data

How will you know youve improved? Have the objectives been met? What is the response variable? What are the savings?

Design schematics Regression analysis Dot plot Sources of variation DoE How do you hold the gains? ANOVA Whats next? ANOG Where else can we apply this? Residual analysis Whats in the revised process map?

Improve
DoE Control charts Hypothesis testing

Improved performance levels

Control
Control charts Mistake proofing Document/instutionalized changes Audit Monitor performance metrics

Life is good!

APPLICABILTY OF SIX SIGMA TOOLS IN OUR SITUATION

FINDING CRITICAL TO QUALITY OF STATION VS EACH DEPARTMENTS DESIGNING OF PROCESS IMPROVEMENTS PROJECTS REVEWING THE PROJECTS AND FIND ACTION PLAN IMPLEMENTING IMPROVEMENTS AND MEASURING CAPABILTY CONTROL CHANGED PRACTICES AND MODIFICATION

CHALLENGES IN ANY SIX SIGMA PROJECT-

A) TO CONVERT TECHNICAL INFORMATION TO STATISTICAL TERMS

B) UTILISATION OF STATISTICAL INFORMATION AND DESIGN A STATISTICAL MODEL OF OPTIMISATION C) APPLYING MODEL FOR PRACTICAL IMPLEMENTATION AND CONTROLLING CHANGE PHENOMENON SUBSEQUENTLY

PROJECTS UNDERTAKEN1) OPTIMISATION IN AUXILIARY POWER CONSUMPTION IN ST#1 UNITS

2) OPTIMISATION OF HEAT RATE IMPROVEMENTS IN ST#2 UNITS

3) OPTIMISATION OF ALUM DOSING IN CLARIFLOCULATOR

Thanks