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IMPROVE
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The failure mode and effect analysis is used to show the potential failures reducing the critical failures of the process (Gupta et al., 2007). Usually when creating a failure mode and effect analysis each potential failure is ranked from 1 to 10 in relation to the damage the failure could cause. Then solutions are thought of to prevent each failure, putting priority on the highest ranked failure.
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6.5 Improve
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The improvement phase is designed to identify actions remedying the root cause of the waste or inef ciency of a process (Gupta et al., 2007). The following tools can be implemented to solve a problem:
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Systems thinking Testing of hypothesis Comparative experiments Design of experiments
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Systems thinking involves making a decision based on data and facts. Often decisions are based on thoughts and studies are not done to nd the true causes of problems. Systems thinking is conducting tests and using tool to nd these problems, and x the problems based on these facts. A statistical hypothesis is an assertion or conjecture concerning one or more populations. Testing of a hypothesis is an inferential technique used to make a statement about an activity or process based on its output (Gupta et al., 2007). One can either fail to reject a hypothesis or reject it. Fail to reject implies that the data does not give suf cient evidence; on the other hand rejection implies the sample evidence refutes the hypothesis. Rejecting the hypothesis means when the hypothesis is true there is a small probability of that sample occurring again. There are always two hypotheses the null and the alternative. The test is against the null; if the test is rejected then the alternative is accepted. Comparative experiments is measuring a control group then conducting an experiment and seeing if there is a difference in results (Gupta et al., 2007). The design of experiments relates to comparative experiments. It is a nonbiased way of creating an experiment while getting the wanted answers to the problem. The three goals of an experiment are
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1 The experimenter should clearly set forth his/her objectives before proceeding with
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the experiment.
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2 The experiment should be described in detail. The treatments should be clearly
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de ned. 3 An outline of the analysis should be drawn up before the experiment is started (Graham, 1993).
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THE SIX SIGMA SYSTEMS APPROACH FOR DEPLOYMENT
6.6 Control
The control phase is designed to maintain the bene ts of the improved process. Tools that are commonly used throughout this process are
Control charts Documentation Change management Communication Reward and recognition Check sheets
Control charts (Fig. 6.7) are used to identify variation whether it is random or assignable (Gupta et al., 2007). Control charts record a task over a given amount of time and are plotted against the speci cation limits to observe if the process is in control. Documentation is the recording of the new process steps to provide standards and guidelines to the employees (Gupta et al., 2007). An example of documentation is ISO 9000. Communication is essential throughout the process but to implement something
Control chart.
SUMMARY
Pin diameter Check Sheet Date: Lathe number: Cutter type: Lower spec. Limit 25 Operator: Remarks:
Sheet No:
Upper spec. Limit
1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
0 Total:
0 0 0 1 0 1
2 4 7 10 14 18 19 15 13 9 5
4 2 2 1
0 0 1
Check sheet.
new and to control it is vital to the success of the new process (Gupta et al., 2007). Rewarding and providing recognition to all involved is also important, giving everyone a sense of pride in the hard work put into the project. Check sheets (Fig. 6.8) can be used to show where different problems could arise, and can keep track of different steps throughout the process or times that different products arrive. Check sheets are a good way to monitor a process and can be used for various aspects of the tasks.
6.7 Summary
This chapter gave an overview of the Six Sigma approach to improving system performance. Six Sigma provides an excellent toolbox of approach and methodologies to analyze and improve project deployment or systems. Many of these concepts are incorporated into the systems approach to minimize solid waste. Speci cally, the use of a data-driven, goal-focused approach that utilizes a variety statistical and process analysis tools.
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