; Chapter 5 Continuous Process Improvement
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Chapter 5 Continuous Process Improvement

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									 Chapter 5 Continuous
 Process Improvement
Create a system for constant and
    continuous improvement
Understand 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 Model
  Process 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,
  method
     PDSA Cycle: Embedded in the
         Continuing System
•   Plan
•   Do
•   Study
•   Act
•   Study
•   Plan again
•   …
     Problem Solving: A Continuous
                 Effort
1. Identify problems as an opportunity
2. Analyze the problem: to find root causes
3. Develop optimal and cost effective solutions
4. Implement changes: system wide
5. Study the results: worked or not? Need
   adjustment?
6. Standardize solution: Keep problems from
   reoccurring.
  Six Sigma: Aim High
Specification   Defective Rate
Limit
+/- 3 sigma     0.27% (2700
                ppm)
+/- 4 sigma     63 ppm

+/- 6 sigma     0.002 ppm (3.4
                ppm if process is
                not centered)

								
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