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B GIO DC V O TO TRNG I HC KINH T TP.

H CH MINH VIN O TO SAU I HC

ti tiu lun:

GVHD: NHM: LP:

TS. NG TH NH I QTKD5 K20

TP. H Ch Minh, thng 03 nm 2012

NHM QUN TR CHT LNG QTKD5 K20

STT

H TN

GHI CH

1 2 3 4 5 6 7 8 9

C Tn Thanh Hi inh Vit Khng Trn Quc Tho Ngc Thun Trn Hunh Hnh Th Bi Anh Tun Bi Ngc Tuyn ng Vn t on Kim Hong Yn

MC LC

LI M U ................................................................................................................... 1 CHNG 1 MT S VN C BN V SIX-SIGMA .................................... 3

1.1 nh ngha 6 Sigma .................................................................................................... 3 1.2 Lch s ra i ca 6 Sigma ........................................................................................ 4 1.3 Mc ch ca 6 Sigma ................................................................................................ 6 1.4 ngha v li ch ca 6 Sigma .................................................................................. 6 1.4.1 1.4.2 ngha .......................................................................................................... 6 Li ch ........................................................................................................... 7

1.5 Trit l ca 6 Sigma .................................................................................................. 10 1.6 Nguyn tc ca 6 Sigma ........................................................................................... 10 1.6.1 1.6.2 1.6.3 1.6.4 1.6.5 1.6.6 Hng vo khch hng ............................................................................. 10 Qun tr theo d liu v d kin .............................................................. 10 Tp trung vo qu trnh, qun tr v ci tin: ........................................ 10 Qun tr ch ng ...................................................................................... 11 Hp tc khng bin gii ........................................................................ 11 Hng ti s hon thin, nhng vn cho php tht bi ........................ 11

1.7 Ni dung c bn ca 6 Sigma .................................................................................. 11 1.8 Cch thc p dng .................................................................................................... 12 CHNG 2 PHN TCH KH NNG P DNG 6 SIGMA TI RKW LOTUS

.......................................................................................................................................... 21 2.1 S lc v cng ty RKW LOTUS ........................................................................... 21


i

2.2.1 2.2.2 2.2.3

Lch s hnh thnh ..................................................................................... 21 Cc dng sn phm ca cng ty RKW LOTUS ...................................... 21 Lu trinh sn xut ..................................................................................... 22

2.1.3 C cu t chc v qun l cht lng......................................................... 23 2.2 Phn tch kh nng p dung 6 Sigma ti RKW LOTUS ...................................... 24 2.2.1 2.2.2 2.2.3 Phn tch theo tin trnh DMAIC ............................................................ 24 Nhn din cc vn hin ti ................................................................... 25 Xc nh vn .......................................................................................... 26
2.2.3.1 Vn leadtime gii quyt cho thi gian giao hng ng hn ............. 26 2.2.3.2 Vn cht lng .................................................................................... 27 2.2.3.3 Xc nh cc vn yu cu khc............................................................ 35

CHNG 3

D ON NHNG KH KHN KHI P DNG 6 SIGMA V

XUT GII QUYT KH KHN .............................................................................. 40 3.1 Nhng kh khn c th gp phi khi p dung 6 Sigma ........................................ 40 3.2 Gii php xut gii quyt kh khn................................................................... 41 3.3 Kt Lun .................................................................................................................... 43 TI LIU THAM KHO ............................................................................................. 44

ii

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

LI M U
Tit kim chi ph, ti u ha s dng ngun lc nhm qun l sn xut hiu qu, m bo cht lng sn phm hay dch v cung cp lun l mc tiu phn u ca cc doanh nghip. Tuy nhin, vic vn dng cc m hnh qun l khc nhau t c cc mc tiu ny thng cha cho kt qu nh mong i. Trong nhiu trng hp, tit kim chi ph v s dng ngun lc hiu qu c th t c, nhng cht lng sn phm hay dch v cung cp li cha p ng c mong i t khch hng. Mt m hnh qun l p ng c cng lc cc mc tiu nh vy s gip doanh nghip va gim chi ph sn xut,va lm hi lng khch hng, thc s cn thit.

Vo u nhng nm 1980, trong n lc nng cao cht lng cao nht cho cc sn phm ca mnh, cng ty Motorola ca M khi xng m hnh qun l cht ch cc qu trnh sn xut v bt u a ra khi nim 6 Sigma. S thnh cng ca m hnh qun l ny ti Motorola to nn mt phong tro trin khai rng ri ti hng lot cc cng ty hng u nh IBM, DEC, Allied Signal, GE Cho n nay, m hnh ny khng nhng c trin khai rng ri trong lnh vc sn xut. Lnh vc dch v cng nng cao dn cht lng phc v vi cch thc kim sot cht ch cc khu, cc qu trnh cung cp theo m hnh 6 Sigma. C th k tn hng lot cc cng ty v ang trin khai thnh cng nh Bombardier, Raytheon, Siemens, Nokia, Navistar, WIPRO, Kodak, Sony, Siebe, 3M, Polaroid, Citibank, ABB, Dupont, Lomega, Amex, Seagate, Black & Decker.
Vy six sigma l g? Ti sao n li mang li hiu qu cao n vy? Liu cc doanh nghip Vit Nam c th p dng thnh cng m hnh qun l trn hay khng? Vi c hi lm bi bo co v six sigma mn qun l cht lng l mt dp tt i tm cc cu tr li cho cc cu hi trn. Qua mt thi gian tm hiu sch bo, cc phng tin truyn thng nh tivi, internet v xin c cm n thy gio Nguyn Ngc

Thc Hin : Nhm 1

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

Tha vi s gip nhit tnh ca thy gip chng em hon thnh bi bo co cng nh tm c li gii p. V thi gian lm c hn cng vi kin thc cn hn hp nn bi vit cn nhiu thiu st chng em mong c thy ng gp kin cc bi sau c hon thin hn. Chng em xin trn thnh cm n! Nhm thc hin Nhm 1

Thc Hin : Nhm 1

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

CHNG 1 MT S VN C BN V SIX-SIGMA
1.1 nh ngha 6 Sigma
Six Sigma l mt h phng php ci tin quy trnh da trn thng k nhm gim thiu t l sai st hay khuyt tt n mc 3,4 li trn mi triu kh nng gy li bng cch xc nh v loi tr cc ngun to nn dao ng (bt n) trong cc quy trnh kinh doanh. Trong vic nh ngha khuyt tt, Six Sigma tp trung vo vic thit lp s thng hiu tng tn cc yu cu ca khch hng v v th c tnh nh hng khch hng rt cao. Ch Sigma ( ) theo k t Hy lp c dng trong k thut thng k nh gi s sai lch ca cc qu trnh, hay cn gi l lch chun. S 6 biu th mc hon ho nht m ta hng ti. Hiu qu hot ng ca mt cng ty cng c o bng mc Sigma m cng ty t c i vi cc qu trnh sn xut kinh doanh ca h. Thng thng cc cng ty thng t ra mc 3 hoc 4 Sigma l mc Sigma chun cho cng ty tng ng vi xc sut sai li c th xy ra l t 6200 ti 67000 trn mt triu c hi. Nu t ti mc 6 Sigma, con s ny ch cn l 3,4 li trn mt triu c hi. iu ny cho php p ng c s mong i ngy cng tng ca khch hng cng nh s phc tp ca cc sn phm v quy trnh cng ngh mi ngy nay. Cc cp trong 6 Sigma:
Mc sigma 2 3 4 5 6 Li phn triu 308.537 66.807 6.210 233 3.4 Chi ph km cht lng Khng c cng ty no qu t hn 2 sigma 25-40% doanh s 15-25% doanh s 5-15% doanh s < 1% doanh s

Thc Hin : Nhm 1

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

Nh vy, 6 Sigma khng phi l mt h thng qun l cht lng, nh ISO 9001, hay mt h thng chng nhn cht lng. Thay vo , y l mt h phng php gip gim thiu khuyt tt da trn vic ci tin quy trnh. i vi a s cc doanh nghip Vit Nam, iu ny c ngha l thay v tp trung vo cc xut cht lng vn u tin vo vic kim tra li trn sn phm, hng tp trung c chuyn sang ci thin quy trnh sn xut cc khuyt tt khng xy ra.

1.2 Lch s ra i ca 6 Sigma


Cu chuyn v 6 Sigma khi ngun t thp nin 1980 ti cng ty Motorla. Vn tht s ca Motorola l cht lng ca h qu t, cng vo thi im th hu ht cc cng ty ca M tin rng sn phm c cht lng th phi tn nhiu chi ph. Bill Smith mt k s ca Motorola nghin cu mi quan h gia i sng ca sn phm v s ln sa cha li trong sut qu trnh sn xut ca sn phm. Nm 1985 Bill Smith a ra kt lun Nu mt sn phm c tm thy khuyt tt v c sa cha li trong qu trnh sn xut th khuyt tt s mt i nhng sau li c khch hng tm thy trong qu trnh s dng sn phm. Tuy nhin, khi sn phm sn xut khng c khuyt tt th cng him khi m khch hng tm thy khuyt tt trong khi s dng. Quan im v cht lng sn phm c c l do phng nga sai hng ngay t u thng qua thit k sn phm v kim sot sn xut c ch trng v s lin h gia cht lng cao v chi ph thp hn dn n s pht trin ca 6 Sigma. Da vo lun im ca Bill Smith, Mikel Harry - mt k s trng v in t to ra mt tin trnh chi tit cho vic ci tin mu m sn phm, gim thi gian sn xut v chi ph sn xut cho cng ty Motorola. Tin trnh ny c Motorola ng k bn quyn v pht trin thnh phng php lun 6 Sigma, bt k mt d n ci tin lin tc no s dng phng php lun 6 Sigma u da trn tin trnh mang tn DMAIC nhm gim thiu t l khuyt tt hoc sai st n mc 3,4 li (defect) trn mi triu kh nng bng cch xc nh v loi tr cc nguyn nhn to nn s bt n (variation) trong cc

Thc Hin : Nhm 1

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

qu trnh kinh doanh. Trong vic nh ngha khuyt tt, 6-Sigma tp trung vo vic thit lp s thng hiu tng tn cc yu cu ca khch hng v v th c tnh nh hng khch hng rt cao. Bob Galvin, gim c iu hnh Motorola thi xc tin phng php 6 Sigma ny v Motorola nhn thy nhng kt qu quan trng l thnh qu ca nhng n lc p dng phng php 6 Sigma ny, c minh chng bng con s tit kim ln ti hn 16 t USD trong 15 nm. Larry Bossidy lm vic cho cng ty Allied Signal (nay lm cho cng ty Honeywell) v Jack Welch lm vic cho cng ty General Electric (GE) khi xng cc chng trnh 6 Sigma cng ty ca h. Kt qu l Allied Signal trong vng mt nm tit kim n 500 triu USD, Honeywell tit kim c 1.8 t trong 3 nm v trong 4 nm tit kim c ti 4.4 t USD. V sau phng php 6 Sigma c trin khai rng ri nhiu t chc khc nhau nh Citigroup, Starwood Hotels, DuPont, Dow Chemical, American Standard, Kodak, Sony, IBM, Ford ... Tuy nhin 6 Sigma vn cha c ph bin rng Vit Nam, mt vi cng ty c vn u t nc ngoi nh Amarican Standard, Ford, LG v Samsung a chng trnh 6 Sigma vo trin khai p dng.

Hnh 1.2.b: Lch s ra i v p dng 6-Sigma

Thc Hin : Nhm 1

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

1.3 Mc ch ca 6 Sigma
Ci tin nng lc qu trnh p ng nhu cu ca khch hng, nng cao s

hi lng ca khch hng. Gim bt thi gian chu k. Gim bt sai hng.

1.4 ngha v li ch ca 6 Sigma


1.4.1 ngha ngha th nht: 6 Sigma bao gm cc phng php thc hnh kinh doanh tt nht v cc k nng gip doanh nghip thnh cng v pht trin, em li cc li ch ln nht cho doanh nghip, 6 Sigma khng ch l cc phng php phn tch thng k c bn v chi tit. ngha th hai: C nhiu cch thc thc hin t c mc tiu 6 Sigma. Chng ta khng cn sao chp nhng nguyn tc c nh m cn p dng linh hot kinh nghim t nhng cng ty i trc. Thc t cho thy cc cng ty p dng 6 Sigma thnh cng u c m hnh ci tin rt linh hot, nh hng vo mc tiu hot ng ca t chc mnh v t chc d n xy dng trn hon cnh c th ca n v mnh. ngha th ba: Tim nng thu c t 6 Sigma c ngha quan trng trong cc doanh nghip dch v v cc hot ng phi sn xut nh trong cc lnh vc nghin cu khoa hc. 6 Sigma c th p dng trong cc hot ng qun l, ti chnh, dch v khch hng, tip th, hu cn, cng ngh thng tin. Cc hot ng ny ngy cng tr nn quan trng trong cnh tranh hin nay. T trng cng nghip dch v ngy cng tng trong khi cc nh cung cp dch v thng mi ch t hiu sut hot ng l 70%.

Thc Hin : Nhm 1

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

ngha th t: Vic p dng 6 Sigma thc s em li mt cuc cch mng trong t chc ca bn. Chng ta tng gp nhng ngi ni mt cch say m v s thay i nhanh chng trong cng ty ca h, nh c s i mi mnh m m vic kinh doanh ca cng ty h ang pht trin. Thc hin 6 Sigma khng phi l khng c nhng ri ro. Bt k mt mc thc hin 6 Sigma no d l 2 Sigma, 3 Sigma hay 4 Sigma u cn c s u t v thi gian, ngun lc v tin bc. 1.4.2 Li ch Trc ht, 6 Sigma gip gim chi ph sn xut. Vi t l khuyt tt gim ng k, doanh nghip c th loi b nhng lng ph v nguyn vt liu v vic s dng nhn cng km hiu qu lin quan n khuyt tt. iu ny s gim bt chi ph hng bn trn tng n v sn phm, t gia tng li nhun. V d, nu mt cng ty c t l hng khuyt tt khng th ti ch l 6%, chi ph nguyn vt liu l 60%, chi ph nhn cng l 10% ca doanh thu, li gp l 20%, mt phn tch n gin c th cho thy hiu qu t vic gim khuyt tt c tc ng ci thin ng k cho ch s li gp nh sau:

Th hai, 6 Sigma gip gim chi ph qun l. Khi t l khuyt tt gim v s khng cn ti din trong tng lai, doanh nghip s tit kim c thi gian cho cc hot ng mang li gi tr cao hn. Th ba, 6 Sgima gp phn lm gia tng s hi lng ca khch hng.

Thc Hin : Nhm 1

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

Phn ln doanh nghip t nhn Vit Nam gp phi nhng vn ti din lin quan n sn phm khng p ng c cc yu cu khch hng khin khch hng khng hi lng v c khi hy b n t hng. V th, thng qua vic gim ng k t l li t cng c 6 Sigma, doanh nghip s lun cung cp n khch hng nhng sn phm tt nht h yu cu v lm tng s hi lng ni h. Th t, 6 Sgima lm gim thi gian chu trnh. Cng mt nhiu thi gian x l nguyn vt liu v thnh phm trong quy trnh sn xut th chi ph sn xut cng cao. Tuy nhin, vi 6 Sigma, c t vn ny sinh hn trong qu trnh sn xut, c ngha l quy trnh lun c hon tt nhanh hn, v vy, chi ph sn xut, c bit l chi ph nhn cng trn tng n v sn phm lm ra s thp hn. Th nm, 6 Sigma gip doanh nghip giao hng ng hn. Mt vn thng gp vi nhiu doanh nghip sn xut t nhn Vit Nam l t l giao hng tr rt cao. Nhng dao ng bt n sinh ra vn ny c th c loi tr trong 6 Sigma. Do vy, 6 Sigma c vn dng gip m bo vic giao hng ng hn v u n. Th su, 6 Sgima gip doanh nghip m rng sn xut d dng hn. Mt cng ty vi s quan tm cao v ci tin quy trnh v loi tr cc ngun gc gy khuyt tt s c c s hiu bit su sc hn v nhng tc nhn tim tng cho cc vn trong nhng d n m rng quy m sn xut. V vy, cc vn t c kh nng xy ra khi cng ty m rng sn xut v nu c xy ra th cng s nhanh chng c gii quyt. Th by, 6 Sigma gp phn to nn nhng thay i tch cc trong vn ha cng ty. 6 Sigma cng vt tri v yu t con ngi khng km u th ca n v k thut. Nhn vin thng t hi bng cch no h gii quyt nhng vn kh khn. Nhng khi h c trang b nhng cng c a ra nhng cu hi ng, o lng ng i tng, lin kt mt vn vi mt gii php v ln k hoch thc hin th h c th tm ra nhng gii php cho vn mt cch d dng hn. V vy, vi 6 Sgima, vn ha t

Thc Hin : Nhm 1

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

chc ca cng ty chuyn sang hnh thc tip cn c h thng trong vic gii quyt vn v mt thi ch ng vi thc trch nhim gia cc nhn vin. Six Sigma chuyn bin cch ngh v lm ca mt cng ty i vi nhng vn trng tm trong kinh doanh: Thit k quy trnh: Thit k cc quy trnh sn xut c c nhng kt qu n nh v tt nht ngay t u. Kho st bin s: Tin hnh nghin cu xc nh nhng bin s hay tc nhn gy nn dao ng v cch thc cc bin tng tc ln nhau. Phn tch v l lun: S dng cc d kin v s liu tm ra cn nguyn ca dao ng thay v da vo nhng v on hay trc gic. Tp trung vo ci tin quy trnh: Tp trung vo ci tin quy trnh c xem l nh hng then cht t c s vt tri trong cht lng. Tinh thn tin phong: Khuyn khch nhn vin tr nn ch ng v y trch nhim trong vic ngn nga nhng vn tim tng thay v ch i i ph vi cc vn xy ra. Tham gia su rng trong vic gii quyt vn : Thu ht nhiu ngi hn tham gia vo vic tm ra cc tc nhn v gii php cho cc vn . Chia x kin thc: Hc hi v chia x kin thc di hnh thc nhng ng dng tt nht (best practice) c kim chng gia tng tc ci tin ton din. Thit lp mc tiu: Nhm n nhng mc tiu vt bc, ch khng phi nhng ch tiu va kh nng, v th cng ty khng ngng n lc ci tin. Cc nh cung cp: Gi c khng l tiu ch duy nht nh gi v chn la nh cung cp m nng lc tng i ca h trong vic cung cp mt cch n nh nguyn vt liu c cht lng trong thi gian ngn nht cng c xem xt. Ra quyt nh da trn d liu: cc quyt nh c a ra da trn phn tch k lng cc s liu v thc t. Tuy nhin, iu ny khng c ngha l n tc ng tiu cc ti kh nng ra cc quyt nh nhanh ca cng ty. Ngc li, bng vic p dng thun thc cc nguyn tc ca qui trnh DMAIC, nhng ngi ra quyt nh c th d dng c s liu mnh cn hn a ra cc quyt nh chnh xc.

Thc Hin : Nhm 1

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

Nh vy, vi 6 Sigma, doanh nghip s tm c 7 li ch vng cho s tng trng ca mnh. Trc vn hi mi, sc cnh tranh cao i hi doanh nghip Vit Nam phi tm c li th cnh tranh cho ring mnh. Trong s cc cng c nng cao tnh cnh tranh y, hy nn ngh u tin n cng c gim lng ph, trnh ri ro t n hon ho 99, 99966% v 7 li ch vng. Nu Ford Vit Nam v rt nhiu doanh nghip th gii tng thnh cng vi 6 Sigma th cc doanh nghip trong nc ti sao li khng bt u vi n?

1.5 Trit l ca 6 Sigma


ng khch hng pht hin ra li ca bn. D bng cch no, t Doanh nghip pht hin li v gim thiu n l cch tit kim nht v ti u nht. Tht s tp trung vo khch hng v hng ti s tuyt ho. Tin n mi nhn vin l mt kim sot vin cht lng.

1.6 Nguyn tc ca 6 Sigma


1.6.1 Hng vo khch hng L u tin hng u ca doanh nghip ng dng 6-sigma. Doanh nghip phi hiu c yu cu v k vng ca khch hng. Ting ni ca khch hng customersvoice cn phi c lng nghe, ghi chp, lu tr v phn tch mt cch lin tc. 1.6.2 Qun tr theo d liu v d kin Vi trit l ny, 6-sigma s gip cc nh qun tr tr li hai cu hi chnh h tr qu trnh ra quyt nh. Nhng d liu / thng tin no l thc s cn thit cho chng ta? Chng ta s s dng cc d liu / thng tin ny nh th no ti a ha li ch? 1.6.3 Tp trung vo qu trnh, qun tr v ci tin: Trong 6-Sigma, qu trnh l trung tm ca s ch , ni s phi hnh ng. Cc qu trnh l nhn t ch yu ca thnh cng.

Thc Hin : Nhm 1

10

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

1.6.4 Qun tr ch ng Ch ng c ngha l hnh ng trc khi s vic xy ra, tri vi phn ng tc l hnh ng sau khi s vic xy ra. Trit l ny cao cu hi Ti sao phi hnh ng? ( ngn nga s vic xy ra) hn l Hnh ng nh th no? (sau khi s vic xy ra). 1.6.5 Hp tc khng bin gii l s hp tc khng c ro cn gia cc b phn t di ln, t trn xung v theo hng ngang, an cho gia cc chc nng khc nhau. 1.6.6 Hng ti s hon thin, nhng vn cho php tht bi Nghe qua c v mu thun, nhng thc cht li tng h vi nhau. Khng c cng ty no c th tin gn n 6-Sigma (tc 3,4 li cho mi mt triu kh nng) m khng pht ng cc tng mi vn cha ng cc ri ro. Nu chng ta mun thc hin cc phng n t c cht lng tt hn, gi thnh thp hn, nhng li s s gp phi hu qu nu chng may mc sai lm, chng ta s khng bao gi dm th. Vn l phi bit cch gii hn thit hi do cc tht bi c th xy ra.

1.7 Ni dung c bn ca 6 Sigma


T nhng trit l nu trn, phng php 6 Sigma cng hng vo 4 ni dung c bn nh sau: Tht s tp trung vo khch hng D liu v qun l d liu thc t Tp trung vo qun l v ci tin qu trnh Nh qun l cn tp trung vo nhng ni dung u tin Rt nhiu t chc ri vo tnh trng mt kim sot v khng bit la chn cc u tin trong cng tc qun l. Cc nh qun l c xu hng mun t c tt c cc kt qu v doanh s, t l tng trng, cc ch tiu cht lng, ch s nhn lc, cc mc tiu chnh tr x hi, ... Vic t ra qu nhiu mc tiu lm cho t chc phn tn cc ngun

Thc Hin : Nhm 1

11

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

lc, khng tp trung vo nhng khu trng im. Cui cng dn n vic lng ph thi gian, tin bc v nhn lc. Phng php 6 Sigma nh hng cho cc nh qun l tp trung vo cc mc tiu c tnh trng yu, hng vo vic tm v gii quyt cc nguyn nhn ci r cc vn gy nn lng ph, sai hng, khng p ng yu cu khch hng. H thng 6 Sigma ch ra cho nh qun l mt nguyn tc l u tin ha cc mc tiu chnh l phng php ct cnh.

1.8 Cch thc p dng


Giai on chun b: y l giai on chng ta ginh thi gian nghin cu v 6 Sigma, xem xt tnh cn thit ca 6 Sigma i vi t chc ca mnh v tin hnh o to nhn lc. Cn o to mt s ai en trong n v lm nng ct cho hot ng ci tin. Cng cn phi d kin cc nhn lc tham gia vo d n ci tin, phn cng ngi ph trch, cc thnh vin d n. Giai on trin khai: Trong giai on ny chng ta s p dng nguyn tc DMAIC thc hnh ci tin. Tin trnh DMAIC l trng tm ca cc d n ci tin quy trnh Six Sigma. Cc bc sau y gii thiu quy trnh gii quyt vn m trong cc cng c chuyn bit c vn dng chuyn mt vn thc t sang dng thc thng k, xy dng mt gii php trn m hnh thng k ri sau chuyn i n sang gii php thc t. Mc tiu
DEFINE XC NH

Cc bc thc hin

Cu hi t ra g l

Lm r vn cn gii Xc nh cc yu cu iu tiu ca d n. Cc mc quan n d n ci tin.

quyt, cc yu cu v mc ca khch hng c lin quan trng i vi khch hng? tiu ca mt d n nn tp Xy dng cc nh Chng ta ang trung vo nhng vn ngha v khuyt tt cng n lc lm gim then cht lin kt vi chnh xc cng tt. loi li/khuyt tt chin lc kinh doanh ca Tin hnh nghin cu g?

Thc Hin : Nhm 1

12

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

cng ty v cc yu cu mc so snh. ca khch hng.

Mc gim

T chc nhm d n bao nhiu? cng vi ngi u Khi no hon (Champion). tt vic ci tin? c tnh nh hng v Ch ph do li, mt ti chnh ca vn ; khuyt tt gy ra v chp thun ca lnh hin ti l bao o cp cao cho tin hnh nhiu? d n. Nhng ai s tham gia vo d n? Ai s u, h tr chng ta thc hin d n ny?

MEASURE O LNG

gip hiu tng tn mc Xc nh cc yu cu Qui trnh hin thc hin trong hin ti thc hin c th c lin ti ca chng ta bng cch xc nh cch quan n cc c tnh l g? Mc thc tt nht nh gi Cht Lng Thit Yu. hiu qu nh th kh nng hin thi v bt Lp cc s quy no? u tin hnh vic o trnh (process map) lin Kt qu u ra lng quan vi cc yu t u no nh hng vo (Input/X) v u ra ti c tnh cht (Output/Y). lng thit yu nht Lp danh sch ca cc nhiu h thng o lng tim (CTQ)? nng. Yu t u vo

Thc Hin : Nhm 1

13

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

Phn tch kh nng h no nh hng thng o lng v thit ti kt qu u ra lp mc so snh v nng (c nh hng ti lc ca quy trnh. CTQ) nhiu Xc nh khu vc m nht? nhng sai st trong h Kh nng o thng o lng c th xy lng/pht ra. hin dao ng ca h

Tin hnh o lng v thng ph hp thu thp d liu cc tc cha? nhn u vo, cc quy Nng lc ca trnh v u ra. qui trnh hin ti Kim chng s hin ra sao? hu ca vn da trn Qui trnh hin cc h thng o lng. ti hot ng ra Qui trnh Lm r vn hay sao? mc tiu ca d n.

(hin ti) c th tt n mc no nu mi th u hot ng nhp nhng? Qui trnh hin ti c th hon ho ti mc no theo nh thit k?

Thc Hin : Nhm 1

14

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

ANALYZE PHN TCH

Trong bc Phn Tch, c trong bc

Lp gi thuyt v cn Yu t u vo

cc thng s thu thp nguyn tim n gy nn no c nh hng o dao ng v cc yu t ln nht ti cc c tnh cht Xc nh mt vi tc lng c bn ca ra (CTQ) Lng c phn tch u vo thit yu (X); cc gi thuyt v cn

nguyn ca dao ng nhn v yu t u vo u to lp v tin hnh kim nht; chng sau .

trong cc thng s c chnh c tc ng r rt (da trn cc s liu thc t)? Kim chng nhng gi Mc nh S kt hp ca cc bin s c nh hng ti cc kt qu u ra khng ? Nu mt yu t u vo thay i, kt qu u ra c thay i tng ng nh mong i khng? Cn bao nhiu ln quan st c kt lun? Mc tin cy ca kt lun l bao nhiu?

thuyt ny bng phn tch hng bao nhiu? a Bin (Multivariate).

Thc Hin : Nhm 1

15

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

IMPROVE CI TIN

Bc Ci Tin tp trung Xc nh cch thc Khi chng ta pht trin cc gii php nhm loi b cn nguyn bit r yu t nhm loi tr cn nguyn gy dao ng; v chun ho cc gii nhn u vo chnh; php. u vo no c nht n cc kt ca dao ng, kim chng Km chng cc tc nh hng ln Khm ph mi quan h qu u ra, chng gia cc bin s; ta phi lm th Thit lp dung sai cho no kim sot quy trnh, cn gi l gii chng? hn trn v di ca cc Chng ta cn thng s k thut hay yu phi th bao cu ca khch hng i nhiu ln tm vi mt quy trnh ra v xc nh ch hot ng /quy trnhchun ti u cho nhng yu t u vo ch yu ny? Qui trnh c cn c ci thin ch no v qui trnh mi s ra sao? gim c bao nhiu Khuyt Tt Trn Mt Triu Kh Nng (DPMO)?

Thc Hin : Nhm 1

16

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

CONTROL KIM SOT

Mc tiu ca bc Kim Hon thin h thng o Khi cc khuyt Sot l thit lp cc thng lng; tr kt qu v khc phc di hn ca quy trnh; tt c gim s o lng chun duy Kim chng nng lc thiu, lm th no chng ta c th c cc vn khi cn, bao Trin khai vic kim bo m cc ci gm c cc vn ca h sot quy trnh bng k thin thng o lng. hoch kim sot nhm duy tr lu di? m bo cc vn Nhng khng cn ti din bng thng nhng quy trnh c lin kim quan. no h cn

cch lin tc gim st c p dng tra vic thc hin cc th tc ci thin? Chng ta cn thit lp nhng bin php g duy tr cc kt qu thm ch khi c nhiu th thay i? Cc bi hc v ci thin c th c chia x cho mi ngi trong cng ty bng

cch no?

Thc Hin : Nhm 1

17

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

CC BC THC HIN DEFINE_XC

CC CNG C THC HIN Bng Tm Lc D n (Project Charter) : L ti liu m t r rng cc vn , nh ngha khuyt tt, cc thng tin v thnh vin ca nhm d n, mc tiu ca d n s thc hin vv. Biu Xu Hng (Trend Chart)- Biu th trc quan xu hng cc li, khuyt tt xut hin sau mt thi gian. Biu Pareto (80/20)- Biu th trc quan mc tc ng tch cc v tiu cc gia tc nhn u vo ti kt qu u ra hoc mc khuyt tt. Lu Quy Trnh (Process Flow Chart)- Cho bit cch thc hot ng v trnh t cc bc thc hin ca qui trnh hin ti.

NH

MEASURE_O LNG

S xng c th hin cc mi lin h gia cc yu t u vo v cc kt qu u ra. Lu qui trnh - hiu r cc qui trnh hin ti v to iu kin cho nhm d n c th xc nh c cc lng ph tim n. Ma trn nhn - qu - nh lng mc tc ng ca mi yu t u vo dn n s bin thin ca cc kt qu u r Phn Tch Trng Thi Sai St v Tc ng (FMEA) s khi s dng cng c ny trong bc o lng s gip chng ta xc nh v thc hin cc bin php khc phc tm thi gim thiu khuyt tt v tit kim chi ph cng sm cng tt. nh Gi Tin Cy Ca H Thng o Lng (GR&R)c s dng phn tch s bin thin ca cc thnh phn ca h thng o lng theo s lm gim thiu s thiu tin cy ca cc h thng o lng. 5 Ti sao (Five Whys) - s dng cng c ny hiu c cc

Thc Hin : Nhm 1

18

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

ANALYZE_PHN TCH

nguyn nhn su xa ca khuyt tt trong mt qui trnh hay sn phm, v c th ph v cc mc nh sai lm trc y v cc nguyn nhn. nh gi cc c tnh phn b (Descriptive Statistics, Histograms) cng c ny dng xc minh c tnh ca cc d liu thu thp c l bnh thng hay bt bnh thng nhm gip ta chn cc cng c phn tch thng k thch hp v sau. Phn tch tng quan/Hi qui (Correlation/Regression Analysis)- Nhm xc nh mi quan h gia cc yu t u vo ca qui trnh v cc kt qu u ra hoc mi tng quan gia hai nhm d liu bin thin. th tc nhn chnh (Main Effect Plot)- Hin th cc tc nhn chnh trong s cc tc nhn c nghin cu. Phn tch phng sai (ANOVA) y l cng c thng k suy lun c thit k kim tra s khc bit ng k gia gi tr trung bnh cng (mean) gia hai hoc nhiu tp hp mu. Hon thnh bng FMEA (Failure Mode and Effect Analysis) p dng cng c ny trn qui trnh hin ti gip ta xc nh cc hnh ng ci thin ph hp ngn nga khuyt tt ti din. Cc phng php kim chng gi thuyt (Hypothesis testing methods) y l tp hp cc php kim tra nhm mc ch xc nh ngun gc ca s dao ng bng cch s dng cc s liu trong qu kh hoc hin ti cung cp cc cu tr li khch quan cho cc cu hi m trc y thng c tr li mt cch ch quan.

IMPROVE_CI TIN

S qui trnh (Process Mapping) Cng c ny gip ta ti hin li qui trnh mi sau khi thc hin vic ci tin.

Thc Hin : Nhm 1

19

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

Phn tch nng lc qui trnh (CPK)- nhm kim tra nng lc ca qui trnh sau khi thc hin cc hnh ng ci tin bo m rng chng ta t c cc ci thin tht s trong vic ngn nga khuyt tt. Thit k th nghim (DOE) y l tp hp cc th nghim c lp k hoch xc nh cc ch /thng s hot ng ti u nhm t c cc kt qu u ra nh mong mun v xc nhn cc ci tin. CONTROL_KIM SOT K hoch kim sot (Control Plans) y l mt hoc tp hp cc ti liu ghi r cc hnh ng, bao gm c lch thc hin v trch nhim cn thit kim sot cc tc nhn bin thin u vo chnh yu vi cc ch hot ng ti u. Lu qui trnh vi cc mc kim sot - Bao gm mt s n l hoc tp hp cc s biu th trc quan cc qui trnh mi. Cc biu kim sot qui trnh bng thng k (SPC) - Tp hp cc biu gip theo di cc qui trnh bng cch hin th cc d liu theo thi gian gia gii hn tiu chun cn trn (USL) v gii hn tiu chun cn di (LSL) cng vi mt ng trung tm (CL) Cc phiu kim tra (Check Sheets) cng c ny cho php chng ta lu gi v thu thp mt cch c h thng cc d liu t cc ngun trong qu kh, hoc qua s kin pht sinh. Theo , cc mu thc lp li v cc xu hng c th c nhn dng v trnh by mt cch r rng.

Thc Hin : Nhm 1

20

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

CHNG 2 PHN TCH KH NNG P DNG 6 SIGMA TI RKW LOTUS


2.1 S lc v cng ty RKW LOTUS
2.2.1 Lch s hnh thnh RKW LOTUS Ltd. l cng ty c thnh ngy 1 thng 10 nm 2004 lin doanh gia RKW SE (c) v LOTUS CHEMICAL TECHNOLOGY Ltd (Vit Nam) vi mc tiu s tr thnh nh cung cp hng u v Gii Php Mng v Si ti th trng chu Thi Bnh Dng. 2.2.2 Cc dng sn phm ca cng ty RKW LOTUS Sn phm chnh ca Cng ty l cc loi ti v mng s dng ht nha PE: Ti nha PE: Cc loi ti nha c sn xut ti cng ty RKW Lotus u c thit k theo yu cu ring bit vi cht lng in cao cp n 8-10 mu. Cng sut hn 2,000 tn/thng sn sng p ng p ng mi nhu cu ca khch hng. Ti PE t hy Oxo Biodegradable: T nm 2008, cng ty RKW Lotus bt u sn xut cc loi ti t hy cung cp cho cc th trng chu u, trung bnh hn 200 tn ti t hy oxo biodegradable/ thng, vi giy chng nhn Licensee Certificate s 3101209559. Theo nhu cu ca cc khch hng, cng ty s dng ph gia t hy EPI, mt loi ph gia t hy u tin v ng u th gii do Canada sn xut. Cht ph gia ny lm cho qu trnh phn hy ca ti nha nhanh hn v phn hy thnh CO2, nc v cht sinh khi biomass Ti ng thc phm: Ti ng thc phm c sn xut vi nha nguyn sinh cao cp, bo m v sinh khi ng thc phm. Cc loi ti ny c th dng trong siu th hoc ti cc ca hng. Ti dy rt: Ti dy rt gip qu khch hng thun tin khi cn cha qun o, dng, hng ha hay cha rc.

Thc Hin : Nhm 1

21

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

Ti xp y hnh sao: Ti xp y hnh sao (star-sealed bags) c thit k t bit vi y tm, hnh ngi sao. Thit k ny gip y ti chc chn hn v chu lc tt hn nhiu so vi cc ti y ngang truyn thng. Loi ti ny rt c a chung v rt thng dng chu u v M Bao th nha: Bao th nha l mt pht trin mi trong ngnh bu chnh. Bao th nha bo m th hay vt gi i khng b thm nc, kh b b gp hay nhu nt. Ti m cy ging: y xp hnh ngi sao, gip ti chc chn hn v t chim din tch, c sn l thot nc ph hp vi yu cu ca khch hng. 2.2.3 Lu trinh sn xut

S 2.1: Lu sn xut

Lu trnh sn xut bt u t khi Phng kinh doanh nhn yu cu v hng ha t khch hng. Sau Phng kinh doanh lin h n Phng cng ngh truyn t yu cu t khch hng xem mnh c sn xut c loi hng m khch hng yu cu khng, ng thi lin h Phng k hoch bit c v thi gian v k hoch giao hng. Sau

Thc Hin : Nhm 1

22

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

, Phng kinh doanh tr li yu cu khch hng v tin hnh nhn n t hng t khch hng. Phng cng ngh sau khi c yu cu v chng loi, mu sc sn phm t Phng kinh doanh s gi n Phng QC cc tiu chun o lng kim tra cht lng. Phng QC ra cc tiu chun cho Phng sn xut v tham gia vo cng tc kim tra cht lng hng ha trong qu trnh sn xut. Phng k hoch gi n Phng sn xut v loi nguyn liu cn cho n hng v chy trn my no l ph hp. Sauk hi c c k hoch sn xut v tiu chun, Phng sn xut bt u tin hng sn xut t kho nguyn ph liu, n trn thi ct v ra thnh phm nhp Kho thnh phm. Phng sn xut ng thi lin h vi Phng Cung ng nhp mua cc nguyn ph liu, my mc thit b cn thit. 2.1.3 C cu t chc v qun l cht lng

S 2.2: C cu t chc Phng qun l cht lng

Thc Hin : Nhm 1

23

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

2.2 Phn tch kh nng p dung 6 Sigma ti RKW LOTUS


2.2.1 Phn tch theo tin trnh DMAIC

Hnh 3.1: Cc bc thc hin theo tin trnh R DMAIC-V

xc nh kh nng p dng 6 sigma ti cng ty, nhm cn phi xc nh 2 iu kin thc hin 6 sigma: Cng ty phi c vn gp phi v d liu cho cc vn c kh nng thu thp c , thc hin thng k c. Ban lnh o cng ty h hi vi cc hot ng ci tin v to iu kin thun li cho vic p dng cc yu cu ci tin.

Thc Hin : Nhm 1

24

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

V iu kin th 2, vic chng minh c tha iu kin ny bng cch nhm s xut thc hin cc d n nh v thit thc tranh th kh nng ng h ca ban lnh o v cng to nim tin cho cc d n ln hn. 2.2.2 Nhn din cc vn hin ti Nhm thc hin phn tch kh nng aqp dng 6 Sigma ti Cng ty phi tm kim v phn tch cc kh khn gp phi hin ti xut hng gii quyt p dng 6 Sigma cho kh nng . Theo thng tin ghi nhn c t phng Kinh doanh v sn xut, ta c bng cc ch s sn xut kinh doanh nm 2011:
Stt Cc vn hin ti Thi gian giao hng Thi gian hi p yu cu n hng Ph phm Tn kho ti cng ty T l Chi ph nhn s Thi gian ngng my Yu t xc nh S n hng ng hn/tng n hng nm 2011 Thi gian di nht cho th mu v pht trin mu mi T l ph phm/ tng sn phm Thi gian tn kho trung bnh 01 n v Gi cng/ tn sn phm thi gian ngng my/thi gian hot ng Kt qu o

90.6%

04 ngy

3 4 5 6

9.2% 12 ngy ~ 97 h/tn 26%

Bng 3.2: D liu thng k n 31/12/2011

Qua bng trn nhm nhn thy thi gian giao hng ng hn ch t c 90.6% => vn tr n hng (~10%) v ph phm (9.2%) ang l mi quan tm ln nht hin nay, nn nhm quyt nh phn tch kh nng p dng 6 Sigma theo 2 yu cu ny.

Thc Hin : Nhm 1

25

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

2.2.3 Xc nh vn

2.2.3.1 Vn leadtime gii quyt cho thi gian giao hng ng hn

Hnh 3.3: S Chui gi tr cho m hng DE200.210

Qua chui gi tr ta nhn thy , tng thi gian cho cc hot ng to nn gi tr ch t 29% trong tng s thi gian hao ph cho hot ng to nn sn phm v mang sn phm n tay khch hng, cc hot ng cn li chim 71% thi gian hao ph dnh cho cc cng vic ph tr, di chuyn, tn khoTrong 71% ny, ch c th c mt phn nh l cc hot ng cn thit cho vic b tr cc hot ng to ra gi tr, cc hot ng cn li(chim khong 90% - theo nh gi chuyn gia) l cc hot ng lng ph gy tn thi gian cho vic hon thnh sn phm.

Thc Hin : Nhm 1

26

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

Qua s chui gi tr, nhm tin hnh xut cc cng c h tr vic nhn din v gim cc lng ph bao gm: Dng Kanban ti kho nguyn liu Dng h thng ko cho cng on gia thi v ct Dng 5S cho cc khu vc sn xut Dng tiu chun ha cho cng vic ti khu ct dn Dng TPM Total Productivity Mainternance gim thi gian ngng my, duy tr hiu qu sn xut ton din. Dng work Balance cho vic gii quyt cc im nghn h tr cho vn lp k hoch n hng.

2.2.3.2 Vn cht lng


Phn tch cho hot ng cht lng ti khu vc trn sn phm

Thc Hin : Nhm 1

27

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

TH NO L CHT LNG KHU TRN? Cht lng khu trn l: Bn nguyn liu phi: ng cng thc ng nguyn liu ng t l ng s lng M trn phn tn u Khng ln tp cht Thi gian giao hng CC HNH NG TO NN CHT LNG KHU TRN?

Bng 3.4: Tng hp cc hnh ng to nn cht lng ca Phuy keo n v tnh: Bn

Thc Hin : Nhm 1

28

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

Trung Stt bnh nm 2011 Sai cng thc Ly nhm nguyn liu Ln ht mu Ht b m Trn khng u T l cp nha theo s lng/ yu cu Thi gian chun b trn 126

Thng 10/2011

Thng 11/2011

Thng 12/2011

4/1/12

5/1/12

6/1/12

11

13

117

11

11

92 46 142 13518/ 13894 33 pht

13 7 16

12 3 18

9 3 13

3 0 0

0 0 0

0 2 5

97.4%

97.2%

97.2%

96.9% 31 pht

97.1% 28 pht

97.1% 35 pht

34 pht

32 pht

32 pht

Bng 3.5: Bng thng k cht lng theo n v Bn n v tnh: % Trung Stt bnh nm 2011 Sai cng thc Ly nhm nguyn liu Ln ht mu Ht b m 0.90% Thng 10/2011 Thng 11/2011 Thng 12/2011

4/1/12

5/1/12

6/1/12

0.53%

0.71%

0.87%

0.84%

0.73%

0.71%

0.60%

0.66% 0.33%

0.86% 0.46%

0.77% 0.19%

0.60% 0.20%

2.00% 0

0 0

0 1.97%

Thc Hin : Nhm 1

29

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

Trn khng u T l cp nha theo s lng/ yu cu Thi gian trn

1.02%

1.06%

0.12%

0.87%

13%

97.29%

97.4%

97.2%

97.2%

96.9% 33 pht

97.1% 29 pht

97.1% 35 pht

34 pht

36 pht

33 pht

32 pht

Bng 3.6: Bng thng k cht lng theo n v %

Sau khi trnh by bng 3.6 cho Trng phng sn xut v c s ng ca Cng ty, nhm kt hp vi i ci tin ca Cng ty thc hin cc bc phn tch su hn. Cng vic (theo trnh t)
Cng vic bn trong (Internal): 1. Xem bng k hoch 2. Ly keo ph 20 82 20 160 380 258 380

M 500 Kg

M 1 tn

3. Cho keo chnh vo 191 (50%) 4. Cho keo ph vo 129 5. Cho keo chnh vo 191 (50%) Cng vic bn ngoi (External): 6. Bo co 7. V sinh 5S 8. Ly phuy 9. Lu mu Cng vic bn trong (Internal): 10. X keo 11. Cn keo & dn tem 12. Cp keo vo my 13. V sinh bn (nu c) Tng cng 40 60 101 427 2,269 128 175 117 45

88 175 117 45 40 60 101 427 3,658

Bng: 3.7: Bng kho st thi gian quy trnh lm vic

Thc Hin : Nhm 1

30

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

Tng t ta tnh c tng thi gian khu trn p ng c yu cu nguyn liu ca khu thi l 14.725 gi vi nng sut 1,963 tn. Trung bnh hon thnh mt vng trn hao tn 35 pht. Nh vy vi k hoch pht trin ca nh my cho nm 2012 phi p ng mc sn lng 2,500 tn (tng 27%) th ta cn phi rt ngn thi gian trn mt m trn xung 25 pht (gim 27%). Sau y nhm i su vo phn tch cc nguyn nhn gc to nn thi gian trn 35 pht bng s xng c

S 3.1: S xng c cho vn thi gian cp nha 35 pht

Thc Hin : Nhm 1

31

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

T s 3.1 nhm phn tch cc nguyn nhn gc v xut gii php gii quyt cho cc nguyn nhn .
Vn ci tin 1.Qui trnh trn cha hp l 2.H thng kim sot thi gian trn h, khng cn hot ng c 3.Khng kim tra c cng nhn trn ng thi gian qui nh hay khng 4.Nguyn liu vng ra trong khi trn 5.Tem nhn dng cc ng ht keo ca cc my khng c d nhm ln Lm li tem ln hn, 6.Tem nhn dng nguyn liu ti bn cha qu nh, V tr kh nhn gn bng kp tem nhn dng va tm mt d dng kim tra 7.B tr bn trn cha hp l mt nhiu thao tc v cng sc vn chuyn nha B tr li 3 7 BP K thut Nhm d n 5 6 Nhm d n Dn li tem y 5 5 Nhm d n xut gii php Son li qui trnh r rng Yu cu BPKT sa cha ngay Hin th thi gian trn thc t - d dng trong vic kim tra iu chnh sa cha li thit k ca bn trn 5 4 BP K thut 7 3 Nhm d n im xp hng 9 Mc u tin 1 K hoch thc hin Nhm d n

BP K thut

Thc Hin : Nhm 1

32

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

8.Cha t chc 5S, cha c layout r rng

Thit lp 5S, dn li layout

Nhm d n

Bng 3.8: Bng nh gi cc tng ci tin

Trong khun kh thi gian lm vic ti Cng ty ca nhm l hn ch nn nhm quyt nh thc hin vn s 1 v s 5 nh sau: Cch ci tin cho vn th nht: Qui trnh trn cha hp l

S 3.2: S quy trnh trn

Thc Hin : Nhm 1

33

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

Cch ci tin cho vn th 5: Tem nhn dng cc ng ht keo ca cc my khng c, rt d gy nhm ln cho ngi cng nhn trong qu trnh cho bn trn nha vo my.

Hnh 3.4: Hnh minh ha thc hin 5S

Kt qu o c sau 7 ngy ci tin


Vn Sai cng thc Ly nhm nguyn liu Ln ht mu Ht b m Trn khng u T l cp nha theo s lng/ yu cu Thi gian trn Trung bnh nm 2011 0.90% 0.84% 0.66% 0.33% 1.02% 97.29% 34 pht Sau khi ci tin 0.23% 0% 0.50% 0% 0.26% 98.33% 20 pht Hiu qu Gim 0.6.7% Gim 0.84% Gim 0.16% Gim 0.33% Gim 0.76% Tng 1.04% Gim 41%

Bng 3.9: So snh kt qu trc v sau ci tin

Thc Hin : Nhm 1

34

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

Qua qu trnh thc hin d n ci tin cht lng cho khu trn trong 10 ngy nhm nhn thy Cng ty sn sng to iu kin cho cc hot ng ci tin. Cng ty sn sng thc hin ci tin khi ci tin c phn tch l c hiu qu

2.2.3.3 Xc nh cc vn yu cu khc Nhm xut cc gii php v cc d n i vi cc vn yu cu khc:


Stt 1 Yu t xc nh S n hng ng hn/tng n hng Thi gian di nht cho th mu v pht trin mu mi T l ph phm/ tng sn phm Thi gian tn kho trung bnh 01 n v Gi cng/ tn sn phm thi gian ngng my/thi gian hot ng Mc tiu ci tin Gim Total Lead time Gim thi gian th mu v pht trin mm Gim ph Gim Cycle time Tng nng sut/ngi Gim thi gian ngng my Phng php SOP, Setup time

2 3 4 5 6

6 sigma 6-sigma, SOP, 5S K hoch : ERP software SOP, Set-up time TPM

Bng 3.10: Bng tng hp cc xut ci tin cho cc vn khc

Tng hp cc phn tch cho cc vn gp phi hin ti ca Cng ty nhm kt hp vi i ci tin thnh lp bng k hoch cc d n ci tin cho nm 2012.

Thc Hin : Nhm 1

35

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

Bng 3.11: Bng xut k hoch ci tin nm 2012

2.2.4

S quan tm ca lnh o (tng hp bi phng vn lnh o cng ty)


Nhm thc hin kho st s ng thun ca lnh o cho kh nng p dng 6

Sigma ti Cng ty nh sau.


Stt Vn Cht lng c l mi quan tm hng u v l chin lc quan trng ca cng ty? Tnh hnh cht lng hin ti ca cng ty c p ng c nhu cu pht trin trong 3-5 nm ti? kin

ng Khng p ng c trong giai on ti T l ny l rt

T l ph phm hin ti ca cng ty 9.2% l mc gii hn?

cao, mc tiu cng ty l 6%

Thc Hin : Nhm 1

36

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

4 5

Cng ty cn phi ci thin tnh hnh cht lng trong 5 nm? Cng ty c chnh sch cho thc hin ci tin cha?

ng c Hin c i thc hin ci

Cng ty c ban chuyn trch thc hin cc d n ci tin

tin l nhn vin t cc ban khc

Cng ty c tin tng p dng 6 sigma s mang li hiu qu nh mong mun Bng 3.12 Bng phng vn trng phng sn xun xut

Cn tm hiu r rang hn

Stt 1 ca cng ty?

Vn Cht lng c l mi quan tm hng u v l chin lc quan trng

kin L mi quan tm hng u Khng p ng c Phi gim xung 5% Trong nm nay c lp ban chuyn trch 6 sigma s l

Tnh hnh cht lng hin ti ca cng ty c p ng c nhu cu pht trin trong 3-5 nm ti? T l ph phm hin ti ca cng ty 9.2% l mc gii hn? Cng ty cn phi ci thin tnh hnh cht lng trong 5 nm? Cng ty c chnh sch cho thc hin ci tin cha? Cng ty c ban chuyn trch thc hin cc d n ci tin

3 4 5 6

Cng ty c tin tng p dng 6 sigma s mang li hiu qu nh mong mun

phng php tt ci tin hiu qu hot ng ca cng ty

Bng 3.13 Bng phng vn gim c cng ty

Thc Hin : Nhm 1

37

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

Stt 1

Vn Cht lng c l mi quan tm hng u v l chin lc quan trng ca cng ty? Tnh hnh cht lng hin ti ca cng ty c p ng c nhu cu pht trin trong 3-5 nm ti?

kin L rt quan trng Mc tiu ca cng ty l 6% Phi gim

T l ph phm hin ti ca cng ty 9.2% l mc gii hn?

khong 3-4% na mi t yu cu

4 5 6

Cng ty cn phi ci thin tnh hnh cht lng trong 5 nm? Cng ty c chnh sch cho thc hin ci tin cha? Cng ty c ban chuyn trch thc hin cc d n ci tin

ng vy c thnh lp thng 3/2011 ang p dng

Cng ty c tin tng p dng 6 sigma s mang li hiu qu nh mong mun

QA, s thc hin 6 sigma khi c iu kin

Bng 3.14 Bng phng vn trng phng QC Stt 1 Vn Cht lng c l mi quan tm hng u v l chin lc quan trng ca cng ty? Tnh hnh cht lng hin ti ca cng ty c p ng c nhu cu pht trin trong 3-5 nm ti? T l ph phm hin ti ca cng ty 9.2% l mc gii hn? Cng ty cn phi ci thin tnh hnh cht lng trong 5 nm? C Cu tr li

Khng Khng- phi nh hn Khng phi

Thc Hin : Nhm 1

38

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

trong nm nay 5 6 7 Cng ty c chnh sch cho thc hin ci tin cha? Cng ty c ban chuyn trch thc hin cc d n ci tin Cng ty c tin tng p dng 6 sigma s mang li hiu qu nh mong mun Bng 3.15: Bng tng hp cc kin phng vn c c Tin tng

Thc Hin : Nhm 1

39

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

CHNG 3 D ON NHNG KH KHN KHI P DNG 6 SIGMA V XUT GII QUYT KH KHN
3.1 Nhng kh khn c th gp phi khi p dung 6 Sigma
Kh khn v kinh nghim p dng: Hin ti, 6 sigma ch p dng thnh cng ng ngha ti cng ty Motorola,

hu ht cc cng ty ti Vit Nam cha trin khai c thnh cng m hnh ny (nu c, ch mang tnh cc b, theo d n) nn s rt kh khn cho vic hc hi kinh nghim. Hu ht cc chuyn gia Vit Nam cha tp hp kinh nghim trin khai 6

sigma thnh cng cho cc m hnh kinh doanh; trong khi , chuyn gia nc ngoi li khng thu hiu trn vn cch thc t chc v vn ha con ngi VN ti cc cng ty s dng lao ng Vit Nam l ch yu. iu ny dn n kh khn cho vic la chn chuyn gia t vn. Kh khn v nhn thc yu t con ngi: Ngi thay i l bn cht ct li ca con ngi, p dng mt m hnh mi

trong khi hiu qu thc t cn nhiu m h s lun to mi nghi ng cho bn thn cc thnh vin tham gia d n, thm ch l chnh bn thn ca lnh o dn n vic trin khai s gp khng t kh khn. Vn kim nhim: 6 sigma l d n ln, cn c s tham gia ca lnh o v

ngi iu phi cng l thnh vin thuc ban gim c, nn a s cc thnh vin d n thng nm gi cc vai tr quan trng trong cng ty v khi d n c trin khai mt thi gian th cc yu t tc ng bn ngoi c nh gi l c mc quan trng cao hn s c u tin gii quyt, trong khi vic tun theo trnh

Thc Hin : Nhm 1

40

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

t h thng l im yu ca con ngi Vit Nam v v th m vic duy tr c 6 Sigma cng s kh khn. Kh khn v Cng ngh : 6 sigma l mt tin trnh kim sot quy trnh i hi s n nh rt ln ca

mi quy trnh cng ngh bao gm: My mc thit b, quy trnh hot ng v con ngi .v.v. trong , MMTB khi s dng mt thi gian thng c bin sai s ln => vic n nh bin ny ngoi nhng gii php kh thi cn ph thuc rt ln vo c tnh thit b. Vic nng cp v thay i thit b l kh khn v cng ln.

3.2 Gii php xut gii quyt kh khn


Cam kt ca Lnh o cp cao Vic trin khai Six Sigma th hin mt cam kt di hn v s thnh cng ca

cc d n Six Sigma vi cc yu cu sau phi c tha mn: Cp lnh o ca cng ty phi hiu v hon ton ng h vic trin khai Six Sigma. Cng ty c phi ci m v sn sng thay i. Cng ty phi sn sng cam kt ngun lc, gm con ngi v tin bc trin khai chng trnh Six Sigma. Chn la v o to ng ngi Thu ht c nhng ngi gii nht tham gia vo xng Six Sigma ca

cng ty v khuyn khch h bng th lao, phn thng, s cng nhn v thng tin gn lin vi kt qu thc hin.

Thc Hin : Nhm 1

41

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

Cc chng trnh o to nn tp trung vo cc kh nng thng k, phn tch,

gii quyt vn v lnh o gip g b nhng ro cn v to ra nhng xung lng tch cc ban u. Thc hin qua hun luyn vic cng nhau truyn t thng tin. Moi ngi

trong cng ty nn hiu Six Sigma s mang li li ch cho h v cng ty nh th no. Chn lc cc d n Six Sigma Tp trung vo nhng vn then cht mang tnh lin kt chin lc; c nh

hng r rt n mc hi lng ca khch hng; v thit yu i vi kt qu kinh doanh di hnh thc mang li hiu qu ti chnh nhanh chng v to ln (thu nhp cao, chi ph thp hn, v.v). Qun l cc d n Six Sigma Dn dt n lc tp trung trong ngi u cho d n (Champion) chu

trch nhim tin hnh nh gi nh k tin d n, s dng quyn hn ca mnh gii quyt cc khc mc lin chc nng cng nh phn b ngun lc cho nhng ni cn thit. Kim tra nh hng ti chnh tht s t d n Lin tc thng tin tin trnh ca d n n cp lnh o iu hnh v nhng

thnh vin c lin quan n d n; Trin khai cc k hoch kim sot hiu qu phi i km vi cc ti liu lin

quan nh: - S Quy Trnh (Process Maps) - Ma Trn Nhn Qu (C&E Matrix) - Phn Tch Trng Thi Sai St v Tc ng (FMEA) - Tm Lc K Hoch Kim Sot (Control Plan Summary)

Thc Hin : Nhm 1

42

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

v cc thay i th tc c duyt m bo rng cc ci tin c duy tr; nh k ti xem xt hiu qu ca d n sau khi hon tt ; Vai tr, trch nhim ca cc phng ban v c nhn lin quan n d n nn

c xc nh r rng; Tin hnh hun luyn Six Sigma thng xuyn thc y chng trnh

xuyn sut trong cng ty.

3.3 Kt Lun
Qua qu trnh nghin cu, nhm c c hi tm hiu r hn v bn cht, quy trnh thc hin Six Sigma cng nh nm c quy trnh sn xut, cc vn trong khu sn xut v rt ra c nhng bi hc kinh nghim. Qua qu trnh phn tch cc vn hin ti cng ty ang gp phi, c s h tr t phng sn xut, cc lnh o Cng ty, nhm rt ra c kt lun rng Cng ty RKW Lotus c kh nng p dng Six Sigma trong quy trnh sn xut ca mnh. Nhng cn c rt ra kt lun, l: Cng ty ang gp phi cc vn v thi gian giao hng v t l ph cao, y l vn ni bt nht, nh hng n chi ph sn xut v uy tn ca Cng ty. Cn c th hai nhm rt ra kt lun l qua qu trnh lm vic ti Cng ty nhm nhn thy Cng ty sn sng i mi Cng ngh, i mi quy trnh, tng p dng ci tin c thnh cng. Thm na, Ban lnh o Cng ty cng rt sn lng p dng phng php Six Sigma ci tin quy trnh. Nhm cng d on mt s kh khn m Cng ty c th gp phi khi p dng Six Sigma v nhng gii php gii quyt kh khn . p dng Six Sigma trong cc hot ng ca mnh, RKW Lotus s gp phi rt nhiu kh khn, nhng nu duy tr vt qua kh khn th chc chn s gt hi c nhng thnh cng to ln, gim c chi ph ng k, mang li li nhun to ln. Tuy c th Cng ty s khng th p dng 6 Sigma cho ton b hot ng ca mnh th cng c th t c hiu qu t mt s d n.

Thc Hin : Nhm 1

43

GVHD : Ts. Ng Th nh

Phn tch kh nng p dng six Sigma ti cng ty TNHH RKW Lotus

TI LIU THAM KHO


[1] T Th Kiu An, Ng Th nh, Nguyn Vn Ho, Nguyn Hong Kit, inh Phng Vng - Qun tr cht lng trong cc t chc Nh Xut Bn Thng K [2] George Eckes Six Sigma for everyone John Wiley & Sons, Inc [3] Alan Larson Demystifying Six Sigma - Amacom [4] Matt Barney, Tom McCarty The new Six Sigma Prentice Hall [5] Ron Basu, J.Nevan Wright Quality Beyond Six Sigma Butterworth Heinemann [6] Sammy G.Shina, Ph.D Six Sigma for Electronics Design and Manufaturing McGraw Hill [7] http://www.isixsigma.com [8] www.lean6sigma.vn [9] http://www.leansigmavn.com [10] Mekong capital gii thiu v Six sigma- www.mekongcapital.com

Thc Hin : Nhm 1

44

GVHD : Ts. Ng Th nh

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