Chapter 5 Continuous Process ImprovementUnderstand the Process: Variations are Major EnemiesProcess ModelProcess Improvement Strategy: Finding Cost Effective SolutionPDSA Cycle: Embedded in the Continuing SystemProblem Solving: A Continuous EffortSix Sigma: Aim HighChapter 5 Continuous Process ImprovementCreate a system for constant and continuous improvementUnderstand the Process: Variations are Major Enemies•Detecting mode (heavy dependence on inspection/testing/control): Fire fighting is not effective•Preventive mode (emphasis on “do it right the first time and all the time): Use FEEDBACK to take corrective actions so that the process can be continuously improved.Process ModelProcess Improvement Strategy: Finding Cost Effective Solution•Control existing process: i.e., statistical process control (SPC)•Optimize the process: i.e., design of experiment (DOE)•Change the system: hardware, software and brainware•New system: machine, human, materials, methodPDSA Cycle: Embedded in the Continuing System •Plan•Do•Study•Act•Study•Plan again•…Problem Solving: A Continuous Effort1. Identify problems as an opportunity2. Analyze the problem: to find root causes3. Develop optimal and cost effective solutions4. Implement changes: system wide 5. Study the results: worked or not? Need adjustment?6. Standardize solution: Keep problems from reoccurring.Six Sigma: Aim HighSpecification LimitDefective Rate+/- 3 sigma 0.27% (2700 ppm)+/- 4 sigma 63 ppm+/- 6 sigma 0.002 ppm (3.4 ppm if process is not
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