6sigma

Phng php qun l mi

Trnh by: Nguyn B Mi TQCSI Vit nam Green Park , 4/218 Thi H, H Ni

Gii thiu v 6Sigma

1987 Galvin CEO 1994
SSA

1. Lch s pht trin ca 6 sigma

1997

Mikel J Harry, Ph.D

1995
AT&T

2001 1996

3M

Jack Welch

LG

Gii thiu v 6Sigma

S thnh cng trong vic p dng 6sigma ti tp on GE ca M
Tng trng
MOTOROLA

1. Lch s pht trin ca 6 sigma

p dng

Thnh tu - Sai hng: gim 3.2t USD - Cht lng: tng 100 ln/4nm Phn nn ca khch hng: 1988: 30% 1993: 7.4%

IMF

G CA

)* 5% (2

1987

1988

TI

Sn xut Nghin cu pht trin sn phm

1995

Sai hng: gim 3.8t USD

GE

Six Sigma
97 98 99

Kinh doanh

SONY

1997

Nm 2000: 2000 ai en

..

04

2010

1 ai en thng mang li cho cng ty 50 K$/nm (vi cc tp on ln) 6 Sigma- Phng php qun l mi

* CAGR: Compound Annual Growth Rate (t l tng trng cng dn)

Gii thiu v 6Sigma

2. 6 sigma l g?

(Sigma)
- Ch ci Hy Lp - c dng ch bin ng ca qu trnh

3
LSL

T.Bnh ()
USL

(*)

6.68 % - 3 + 3

Khu vc c th sai hng

6
3.4 (**) ppm - 6 + 6

ng phn b

Mc 6 Sigma c ngha l ng phn b c lng ca qu trnh nm trong khong gii hng cho php (USL v LSL) c rng l 6. Vi qu trnh nh vy, phn nm ngoi gii hn cho php (cn gi l phn sai hng) s ch mc 3.4ppm (3,4 sai hng trn 1 triu c hi)

* USL : Upper Specification Limit (Gii hn trn) LSL : Lower Specification Limit (Gii hn di ) ** ppm : part per million (phn triu)

6 Sigma- Phng php qun l mi

Gii thiu v 6Sigma

ng sn xut kinh doanh.

2. 6 sigma l g?

6 Sigma l mt qu trnh phn tch c k lut v kht khe trong vic gii quyt cc vn trong hot

Phng php c Gii quyt vn da trn kinh nghim

Tm kim vn Da vo logic v s liu Ci tin cc qu trnh da trn kinh nghim v him bit v cng vic

6 Sigma Gii quyt vn da trn kinh nghim v qu trnh phn tch thng k Nhp s liu vo cc phn mm phn tch thng k Phn tch th nghim

Phn tch, ci tin da trn s liu

Cc quyt nh nhanh chng, xc thc v chnh xc hn ngay c trong c tnh hung khng r rng

6 Sigma- Phng php qun l mi

Gii thiu v 6Sigma

3. ngha ca o lng thng k

Nguyn l 1: Chng ta khng bit nhng g chng ta khng bit Nguyn l 2: Nu chng ta khng th th hin nhng g chng ta bit bng cc con s th chng ta thc s cha thu hiu nhiu v n Nguyn l 3: Nu chng ta khng thu hiu v n th chng ta khng th kim sot c. Nguyn l 4: Nu chng ta khng th kim sot c chng, chng ta s ph mc mi s thay i.

Gii thiu v 6Sigma

3. ngha thng k ca 6 sigma K thut thng k: l hc thuyt v phng php nhm a ra cc quyt nh chnh xc nht trong cc tnh hung khng r rng. Cc cng c 6Sigma xy dng trn nn tng l cc cng c thng k.

o lng 10 mu Tiu chun 1004 Gii hn di Gii hn trn

- Phng php truyn thng: Qu trnh trn l tt v tt c cc mu o lng c kt qu u nm trong phm vi cho php - Phng php 6 Sigma: Qu trnh trn l khng tt v qua phn tch kt qu o lng bng cng c 6sigma, ng phn b d liu cho thy t l sai hng ca qu trnh ny vn mc cao, khong 28000ppm (sn xut 1triu sn phm, c 28 000 sn phm li)

X : cc kt qu o c

: ng phn b d liu s dng k thut phn tch thng k

6 Sigma- Phng php qun l mi

Gii thiu v 6Sigma

3. ngha thng k ca 6 sigma

Chi ph sai hng v cht lng thng thng o lng bng cc phng php truyn thng ch l phn ni ca tng bng tri
Bo co chi ph sai hng thng thng Sn phm hng Sn phm b gim ga tr s dng Chi ph kim tra, lm li, bo hnh

Phng php qun l mi 6sigma: kim sot c cc chi ph n Thay i thit k Chu trnh sn xut, bn hng cha tt Tn kho vt mc Giao hng chm

6 Sigma- Phng php qun l mi

Gii thiu v 6Sigma

1. l s o lng v thng k

4. nh ngha 6 sigma

6sigma cho chng ta bit sn phm, dch v, cc qu trnh ca chng ta thc s th no 6Sigma gip chng ta thit lp cc mc tiu nhm t c s tho mn khch hng cao nht

2. l mt cng c ci tin hiu qu

6Sigma thc s l mt cng c ton din s dng trong lnh vc ci tin, c th p dng cho tt c cc qu trnh ca hot ng sn xut kinh doanh, t khu thit k sn phm, sn xut cho n khu bn hng v dch v sau bn hng.

3. l mt chin lc kinh doanh

6Sigma l mt cng c c gi tr thit thc nhm to li th trong cuc chin cnh tranh vi cc i th. Bng vic thng xuyn nng cao mc sigma ca cc qu trnh, cht lng sn phm c ci tin, chi ph sai hng gim v do khch hng cng ngy cng cm thy tho mn hn. 6Sigma hng n s tho mn c cc yu cu ln cc mong mun ca khch hng.

4. l mt hc thuyt
6Sigma ch cho chng ta cch lm vic thng minh hn, thay v phi lm vic chm ch hn, nhng li thu c kt qu cao hn. 6Sigma cng h tr cho chng ta gim thiu ti a cc sai li trong qu trnh.

6 Sigma- Phng php qun l mi

Gii thiu v 6Sigma

5. Mt s hot ng 6 sigma

Hiu c bin ng v cc nguyn nhn gy ra cc bin ng l cha kho thnh cng khi qun l bt k hot ng sn xut kinh doanh no.

Ti sao tai nn ny li xy ra?

Ngi ta ni rng mc nc y su trung bnh l 10m

6 Sigma- Phng php qun l mi

Gii thiu v 6Sigma

im ho vn

5. Mt s hot ng 6 sigma

Z
Phn li nhun c c do tng gi bn Chi ph

Mc ch ca 6sigma
Gim chi ph bin ng variable cost Gim bin ng ca variable cost Gim chi ph c nh fixed cost Tng gi bn

$
Li nhun Gi bn Chi ph c nh (Fixed cost) Chi ph bin ng (Variable cost)

6 Sigma- Phng php qun l mi

Gii thiu v 6Sigma

6sigma hng ti s tho mn khch hng hn l tho mn cc qu trnh. Thng 3: Khch hng ni rng h vn khng cm thy cht lng giao hng tt hn, mc d cng ty gim thi gian giao hng trung bnh t 17ngy 8 ngy
Thi gian giao hng Thng 1 Thi gian giao hng
40

5. Mt s hot ng 6 sigma

Tip tc l cha
Mr. Jack Welch Tng gim c iu hnh ca GE,

Thi gian giao hng Thng 5

Tn xut

10

15

Thng 3

30

10 5 5

20

10

0 0 5 10 15 20 25

0 0 5 10 15 20 25

0 0 5 10 15 20 25

[ngy]

Cng ty cm thy hi lng Nhng khch hng vn cha cm thy hi lng

Lc ny khch hng mi thc s cm thy hi lng

6 Sigma- Phng php qun l mi

Gii thiu v 6Sigma

Yu cu ca khch hng Mong i ca khch hng S khng tho mn Cc nguyn nhn

5. Mt s hot ng 6 sigma

6sigma tp trung vo vic la chn v gii quyt cc vn ct li, chi ph thp nhng hiu qu cao.
6 Ticket

( X1, X2, X3, ... Xn )

80%

Chi ph thp, hiu qu cao

Sng lc
20%
Cc nguyn nhn ch yu da trn k thut phn tch thng k v t duy logic Da trn quy lut 80:20 (80% s khng tho mn l do 20% nguyn nhn chnh gy ln)

Ci tin da trn cc cng c 6sigma

CTQ
Cc nguyn nhn chnh

6 Sigma- Phng php qun l mi

Gii thiu v 6Sigma

6. 6 sigma v cc phng php khc

Phng php qun l 6sigma - i u l cc cng ty ca M

Ti u ho mt cch ton din hot ng sn xut kinh doanh -Thit k sn phm -Sn xut -Bn hng -Dch v sau bn hng, bo hnh

Thnh lp cc nhm qun l cht lng Cc nhm ny tp trung nghin cu v v ci tin qu trnh sn xut, hng n cc gii php ton din.

TQM TQC

Ci tin cht lng ca sn phm

QC

Tp trung vo ci tin nng xut dy chuyn - i u l cc cng ty ca Nht

6 Sigma- Phng php qun l mi

Gii thiu v 6Sigma

M t C s Ch s Mc tiu D liu Phng php kim sot Hot ng TQM Da trn 5S, kinh nghim v t duy logic T l sai hng Tho mn cc yu cu ca khch hng S liu ri rc (s sai hng) Kim sot cc qu trnh bng cc gii hn (trn v di) Tham gia ca tt c mi ngi, trin khai t cc cng on (Bottom up) Thc hin theo nhm cht lng Tp trung vo ci tin khu sn xut

6. 6 sigma v cc phng php khc

6sigma Da trn vic ng dng k thut thng k v kinh t lng Mc sigma (nng lc ca qu trnh) Tho mn s mong i ca khch hng S liu ri rc v lin tc (sai hng v bin ng) Kim sot bin ng ca cc qu trnh Trin khai t trn xung di, nhm t c mc tiu chin lc ca cng ty (Top down) Thc hin thng qua cc d n 6sigma p dng cho tt c cc khu ca qu trnh hot ng sn xut kinh doanh Cc cng ty ca M

p dng

i u

Cc cng ty ca Nht

6 Sigma- Phng php qun l mi

Cc bc p dng

1. Cng ty p dng 6 sigma

Thit lp mc tiu chin lc (vison)

Cng ty 6 Sigma

Champions
(Ngi ng u Cng ty)

Thit lp nh hng cho hot ng 6sigma H tr thc hin cc d n 6sigma

c o to v thu hiu phng php 6sigma

ai en (BB v MBB)

Trin khai vic thc hin mc tiu 6sigma o to 6sigma xy dng ngun lc 6sigma ni b Hoch nh v qun l cc d n 6 sigma

Tham gia thc hin cc d n 6sigma

ai xanh ai vng

p dng cc cng c 6sigma vo cc qu trnh Thng xuyn xem xt ci tin cc qu trnh

President & CEO

nh k Champion thc hin xem xt vic thc hin cc mc tiu v cc d n 6sigma thng qua bui hp Champion review.

Cc bc p dng
Phng php Define (D) Measure (M) Analyze (A) Improve (I)
N OK ? Y

2. D n 6 sigma

Mi d n 6sigma c trin phai theo 5 bc ca qu trnh DMAIC, thng ko di 1-3 thng D-xc nh, M-o lng, A-phn tch, I-ci tin, C-kim sot.
Mt vi cng c - Phng vn, iu tra - Process mapping (lu qu trnh) - QFD (trin khai cht lng) - Gage R&R (kim tra h thng o lng) - Process capability index (phn tch nng lc qu trnh) - Phn tch bng th v biu - Th nghim gi thuyt - Brainstorming - Logic tree (Lu hnh cy)

Bc 1. Xc nh yu cu/mong i ca khch hng. 2. Xc nh Y (mc tiu ca d n) 3. ng k d n vi b phn qun l 4. Thu thp s liu s dng k thut thng k 5. o lng mc hin ti bng ch s sigma 6. S dng cc cng c 6sigma, phn tch v la chn cc nguyn nhn chnh, cc im chnh cn ci tin (CTQ) 7. La chn tng ci tin cho cc CTQ 8. Lp k hoch, thc hin ci tin v thm nh li kt qu 9. Tiu chun ho cc hnh ng ci tin thc hin, v hng dn p dng tng th. 10. Xy dng h thng gim st v tin hnh theo di gim st kt qu

Control (C)

- Control chart (Biu kim sot)

6 Sigma- Phng php qun l mi

Cc bc p dng
Giai on Ni dung

3. Cc giai on trin khai p dng 6sigma

Thi gian 9 Ngy (thng th nht) Gii thiu: 1ngy L thuyt: 1 ngy Cc cng c: 7 ngy 10 Ngy (thng th nht)

o to

o to c bn v 6 sigma cho cn b cng nhn vin Cc ni dung o to bao gm: -Gii thiu v phng php 6 sigma -L thuyt phng php qun l 6 sigma -Cc cng c 6sigma c bn v thc hnh Kho st v tnh trng hin ti ca doanh nghip S dng ngun lc o to xy dng chng trnh 6 sigma Thit lp cc ch tiu v hoch nh vic trin khai cc mc tiu 6 sigma Da trn cc mc tiu 6 sigma cc b phn pht trin v trin khai cc d n 6 sigma. o to v k nng qun l d n 6 sigma. Trin khai, h tr v gim st kt qu ca cc d n. nh gi v cp chng ch 6 sigma ai vng (c bn) Xem xt li vic thc hin p dng 6 sigma nh gi v cp chng ch ai xanh 6 sigma Xy dng chng trnh o to nng cao (ai en 6 sigma) Tng kt v nghim thu d n xy dng h thng qun l theo phng php 6sigma

Xy dng chng trnh 6 sigma

Trin khai cc d n 6 sigma

15 Ngy (thng 2, 3, 4) o to: 2ngy H tr: 12 ngy nh gi: 1 ngy 8 Ngy (thng th 5) o to: 5ngy H tr: 2 ngy nh gi: 1 ngy 1 Ngy (thng th 5)

Nng cp h thng Tng kt& nghim thu

Cc bc p dng
Logic tree trong hoch nh mc tiu chin lc
G age nam e: D a te o f s tu d y : T3715 3 .1 5 .2 0 0 5

4. Mt s cng c 6 sigma
Gage R&R: kim nghim h thng o lng
G a g e R & R S tu d ie s fo r P ro je c t T T M (4 .1 5 .2 0 0 5 )
R e p o rte d b y : T o l ra n c e : e M i c: s 4 .1 5 .2 0 0 5 0 .0 1 P ro j c t T T M e

C o m p o n e n ts o f V a ria tio n
100 P e rc e n t
% C o n tri u ti n b o % S tu d y V a r % P ro c e s s % T o l ra n c e e

R e s p o n s e b y P a rt
1 7 .0

50

1 6 .5 1 6 .0

0 G age R & R R epeat R e p ro d P a rt- to - P a rt

5 P a rt

10

R C h a rt b y A p p ra is e r
S a m p le R a n g e 0 .1 0 1 2 3 U C L = 0 .0 9 6 9 1 7 .0

R e s p o n s e b y A p p ra is e r

0 .0 5

_ R = 0 .0 2 9 7 LC L=0

1 6 .5 1 6 .0 1 2 A p p ra is e r 3

0 .0 0

X b a r C h a rt b y A p p ra is e r
1 1 7 .0 S a m p le M e a n A v e ra g e _ _ UC 141 X = 1L6=.6 6 .6 9 7 L C L = 1 6 .5 8 5 2 3 1 7 .0

A p p ra is e r * P a rt In te ra c tio n
A p p ra i e r s 1 2 3

1 6 .5

1 6 .5

1 6 .0 1 6 .0 1 2 3 4 5 6 P a rt 7 8 9 10

Xc nh nng lc hin ti: Process capability

P ro c e s s C a p a b i i o f R e s p o n s e l ty
U SL
P ro c e s s D a ta LS L * T a rg e t * USL 1 7 .3 S a m p l M ea n e 1 6 .2 9 6 1 S am pl N e 150 S tD ev (W i i ) th n 0 .2 7 1 3 67 S tD ev (O v era l) l 0 .2 7 9 2 48

Phn tch s liu dng Histogram

Histogram of P.Sales, A.Sales
60
56 Variable P.Sales A .Sales

W i i th n O ve ra l l
P ote n ti l (W i i C a p a bii a th n) lty Z .B e n c h 3 .70 Z .L S L * Z .U S L 3 .70 C pk 1 .23 O ve ral C a p a b ii l lty Z .B e n c h Z .L S L Z .U S L P pk C pm 3 .59 * 3 .59 1 .20 *

50 40 Frequency 30
23

20 10 0
10

19

20

11 7 3 0 5 0 0 0 0 6 0 3 0 4 0

15.6
O bs e rve d P e rfo rm an c e P P M < LS L * PPM > USL 0 .0 0 P P M T ota l 0 .0 0

15.9

16.2

16.5

16.8

17.1

E x p . W i i P e rfo rm an c e th n P P M < LS L * PPM > USL 1 08 .1 2 P P M T o ta l 1 08 .1 2

E x p . O v e ra l P e rform a n c e l P P M < LS L * PPM > USL 1 6 2.3 0 P P M To tal 1 6 2.3 0

1 0

2 0

1 0

1 0

7500

15000

22500

30000 Data

37500

45000

Cc bc p dng
Phn tch s liu dng Matrix plot
Matr ix P lot of A.S ales , P .S ales , A.P r ofit, A.P r ice
9000 12000 15000 165 180 195 40000 30000 20000 15000 12000 P. Sa le s 9000 60 40 A. Pro fit 20 195 180 A. Price 165 20000 30000 40000 20 40 60

4. Mt s cng c 6 sigma
La chn cc yu t chnh dng PARETO

A. Sa le s

Phn tch hi qui dng regression

Phn tch tng quan nhiu qu trnh

Cc bc p dng
Phn tch mc nh hng bng DOE

4. Mt s cng c 6 sigma
La chn gi tr ti u bng cube plot

Phn tch nhiu qu trnh dng Box plot

Kim sot qu trnh bng control chart

Trn Thnh Cm n