FICCI CE

Accuracy & Precision - The twin

objectives of world class manufacturing.
FICCI CE

Picturization of accuracy & precision

Accurate and Precision
Accuracy & precision of a manufacturing process can be best
explained by using the analogy of a rifle firing at a target.
FICCI CE

Accuracy and precision

With the center of the target taken to be the true value of the
characteristic being measured and by the rifle shots representing
the measured values, there are four combinations of accuracy and
precision as depicted in the following slides.
FICCI CE
Inaccurate and imprecise

+
FICCI CE
Accurate and imprecise

+
FICCI CE
Precise but inaccurate

+
FICCI CE
Accurate and precise

+
FICCI CE

Objectives of accuracy & precision

As observed from the Picturization in the preceding slides, the

objective of moving towards world class manufacturing is
to continuously achieve greater consistency of the processes
by aiming for consistently higher levels of accuracy &
precision
FICCI CE

Sigma

Standard deviation is also referred to as the Greek letter sigma in quality

management literature. Consequently process variation can be described
by how many sigmas ( i.e how many multiples of standard deviation or
SD ) fit within the specification limits.The higher this number, the better
is the quality and vice versa.
Sigma is a statistical measure of the quality consistency for a particular
process / product.
FICCI CE

Sigma process

From a sigma process we come to know that at what distance, in

terms of the standard deviation, the specification limits are placed
from the target value.
FICCI CE

Move beyond 3 sigma

Until a few years back all statistical process controls were designed
on the basis of 3 sigma limits. It is only in the recent years that this
concept has been challenged and the organizations have started
looking for quality levels beyond 3 Sigma.
FICCI CE

3 Sigma process

Mean=8
LSL SD = 2 USL

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

- 3 SD + 3 SD

Note : LSL is Lower specification limit and USL is Upper specification limit.
FICCI CE

4 Sigma process

LSL Mean=8 USL

SD = 1.33

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

- 4 SD + 4 SD
FICCI CE

5 Sigma process

Mean=8
LSL SD = 1.07 USL

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

- 5 SD + 5 SD
FICCI CE

6 Sigma process

Mean=8
LSL SD = 1 USL

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

- 6 SD + 6 SD
FICCI CE

Precision

Lesser the standard deviation of the process, more precise or

consistent is the process
FICCI CE

3 Sigma Vs 6 Sigma

The goal of Six Sigma program is to reduce the variation in

every process to such an extent that the spread of 12 sigmas i.e.
6 Sigmas on either side of the mean fits within the process
specifications. The figure on next slide shows what this looks
like.
FICCI CE

3 Sigma Vs 6 Sigma
6 Sigma curve

LSL USL

3 Sigma curve

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

In a 3 sigma process the values are widely spread along the center line,
showing the higher variation of the process. Whereas in a 6 Sigma
process, the values are closer to the center line showing
less variation in the process.
FICCI CE

3 Sigma Vs 6 Sigma

The comparison on the previous slide also shows a process in

which the process spread of Six Sigmas (ie. 3 Sigmas on either
side just fits within the specifications). In this case one must be
extremely careful to ensure that the process average never slips
off the target, otherwise the curve will shift and non-
conforming items will increase. With Six Sigma requirement
the process mean can shift by as much as 1.5 sigma before the
likelihood of non-conforming items is increased. Even if the
process mean does shift off center by as much as 1.5 sigma,
only 3.4 non-conforming items per million parts should result.
FICCI CE

Amount of process shift allowed

1.5 SD 1.5 SD

LSL USL

SD = 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
FICCI CE

Sigma levels and defect rate

Quality level % Quality Defective PPM*

3 Sigma 99.73 66807

4 Sigma 99.9937 6210

5 Sigma 99.999943 233

6 Sigma 99.9999998 3.4

*Parts Per Million

FICCI CE

Sigma levels & Cost of quality

Sigma Defect rate(PPM) Cost of quality Competitive level

6 3.4 <10%
World
5 233 10-15% Class

4 6210 15-20%
Industry
3 66807 20-30% Average

2 308537 30-40%
Non
>40% Competitive
1 6,90000
FICCI CE

Six Sigma - DMAIC Strategy

DMAIC is a data driven quality strategy for improving processes and

an integral part of a six Sigma quality initiative.DMAIC Is the
Acronym for 5 phases of Six Sigma as given below:-

Define
Measure
Analyze
Improve
Control
FICCI CE

Define phase

This phase defines the project. It identifies critical customer

requirements and links them to business needs. It also defines a
project charter and the business processes to be undertaken for Six
Sigma.
FICCI CE

Measurement phase

This phase involves selecting product characteristic, mapping respective

process, making necessary measurements and recording the results of the
process. This is essentially a data collection phase.
FICCI CE

Improvement phase

This phase involves improving processes/product performance

characteristics for achieving desired results and goals. This phase
involves application of scientific tools and techniques for making
tangible improvements in profitability and customer satisfaction.
FICCI CE

Control phase

This phase requires the process conditions to be properly documented and

monitored through statistical process control methods. After a “settling in”
period, the process capability should be reassessed. Depending upon the
results of such a follow-up analysis, it may be sometimes necessary to
revisit one or more of the preceding phases.
FICCI CE

The breakthrough strategy

Each phase is designed to ensure that :-

• Companies apply the breakthrough strategy in a systematic way.
• Six Sigma projects are systematically designed and executed and
• The results of these projects are incorporated into running the day-
today business.
FICCI CE

Strategy at various levels

Almost every organization can be divided into 3 basic levels :-

1. Business level
2. Operations level
3. Process level.
It is extremely important that Six Sigma is understood and integrated
at every level.
FICCI CE

Strategies at various levels

• Executives at the business level can use Six Sigma for improving market
share, increasing profitability and organizations long term viability.
• Managers at operations level can use Six Sigma to improve yield and
reduce the labor and material cost.
• At the process level engineers can use Six Sigma to reduce defects and
variation and improve process capability leading to better customer
satisfaction.