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D   M A I C

Six Sigma
Green Belt TRAINING
GB TRG MATERIAL Slide 1 Proprietary to Wipro Ltd
 

How Successful Leaders see Six Sigma

Six Sigma is the most important initiative GE has


ever taken…it is part of the genetic code of our future leadership.
-Jack Welch, Former CEO,
General Electric 

 You can see the “before” & “after” of an organization


when Six Sigma grabs hold & takes place.
-Richard Johnson, Director of Six Sigma,
 Allied Signal 

Successful leaders have made Six Sigma their way of conducting business.
- Azim Premji, Chairman,
Wipro Limited 

GB TRG MATERIAL Slide 2 Proprietary to Wipro Ltd


 

What is Six Sigma?

 Six Sigma as a metric 


  At Six Sigma level, a process produces less than 3.4 defects in a million or
99.99966% Yield 

 Six Sigma as a methodology 


 Improving process capability to desired levels

 Six Sigma as a phi los ophy


 Business excellence through organizational transformation

 Six Sigma : Variation Based thinking 

GB TRG MATERIAL Slide 3 Proprietary to Wipro Ltd


 

6 Sigma as a metric

The Sigma Scale provides a common scale/ metric for comparison.


Which process is performing best?
PROCESS PERFORMANCE

Call servicing 32 seconds ASA vs. goal of 35

Billing 98% accuracy

 Accounts Receivable 33 days average aging vs. goal of 40

Customer Service 82% rated 4 or 5 on responsiveness

Sigma level DPMO


2 308,537
3 66,807
4 6,210
5 233
6 3.4

GB TRG MATERIAL Slide 4 Proprietary to Wipro Ltd


 

Six Sigma: As Methodology

An efficient & effective method :


Six Sigma is a structured application of

process improvement tools,

applied by dedicated resources on a project basis,

to increase customer satisfaction and reach strategic business goals.

Black Belt’s Statistical Black Belt’s


Expertise Tools Expertise

Business Statistical Statistical Business


Problem Problem Solution Solution

P R O J E C T

GB TRG MATERIAL Slide 5 Proprietary to Wipro Ltd


 

Six Sigma: As Philosophy

A philosophy :

For many companies, Six Sigma is a management philosophy.

Successful leaders have made Six Sigma their way of conducting business.
- Azim Premji, Chairman,
Wipro Limited 

‘Six sigma is the best training that an organization can give to its employees,
it’s even better than sending them to Harward Business School.’ 
- Jack Welch, Former CEO, GE 

GB TRG MATERIAL Slide 6 Proprietary to Wipro Ltd


 

Six Sigma is Variance Based Thinking

Consider below performance on ‘On time delivery’

Mean 0.70 days

Target 0 days

-20 -10 0 10 20

On Target !!!! Good Performance ??

GB TRG MATERIAL Slide 7 Proprietary to Wipro Ltd


 

Six Sigma is Variance Based Thinking

What customer sees!!

-20 -10 0 10 20

Customer always looks at variance , mean is … meaningless

GB TRG MATERIAL Slide 8 Proprietary to Wipro Ltd


 

Are We Looking at the Variation?

Don’t worry,
That rope is
one inch thick
on average.

“If I had to reduce my message to management


to just a few words, I’d say it all had to do with
reducing variation” 
W. Edwards Deming 

GB TRG MATERIAL Slide 9 Proprietary to Wipro Ltd


 

DMAIC Overview

DEFINE
The Problem

MEASURE
Y ( Outcome)  DMAIC applies to an existing process
Validate Measurement System that needs improvement
ANALYZE
Baseline Y and Set Goal
Identify X’s(Variation Sources)

IMPROVE
Quantify X’s

CONTROL
Control X’s

GB TRG MATERIAL Slide 10 Proprietary to Wipro Ltd


 

DMAIC
Establish CTQ Characteristics

GB TRG MATERIAL Slide 11 Proprietary to Wipro Ltd


 

CTQ (Critical to Quality)

 A CTQ is a
Business CTQ
Product or Service

characteristic Customer CTQ

that satisfies a
Internal CTQ
Customer Requirement
OR 
Project CTQ
Process Requirement

GB TRG MATERIAL Slide 12 Proprietary to Wipro Ltd


 

What are Business CTQs?

 Business CTQs drive the business goals & vision

 Typical Business CTQs are in the area of:

 Operational Excellence

 Cost Reduction

 Productivity Improvement

 Employee Satisfaction

 Customer Satisfaction

 Sales Growth

 Profitability

GB TRG MATERIAL Slide 13 Proprietary to Wipro Ltd


 

Define your Customer 

GB TRG MATERIAL Slide 14 Proprietary to Wipro Ltd


 

Who is your customer?

  A customer is someone who

 Uses your product or service

 Decides to buy your product or service

 Pays for your product or service

 Gets impacted by your product or service

 Internal & External customers

 Primary & Secondary customers

 Key concepts

 Different markets / segments


 Different customer requirements
 Product / Service chain

GB TRG MATERIAL Slide 15 Proprietary to Wipro Ltd


 

Explore Customer CTQ

GB TRG MATERIAL Slide 16 Proprietary to Wipro Ltd


 

Customer CTQs

 Six Sigma begins with the customer 

 Customers find it easier to define what they do not want

 Customer CTQs are defined by customers

 Sources of customer CTQs

 Survey results

 Service reviews

 Meetings

GB TRG MATERIAL Slide 17 Proprietary to Wipro Ltd


 

Customer Requirement –  perceived by Sales Team

GB TRG MATERIAL Slide 18 Proprietary to Wipro Ltd


 

Customer Requirement – captured by Design Team

GB TRG MATERIAL Slide 19 Proprietary to Wipro Ltd


 

Customer Requirement – created by Production Team

GB TRG MATERIAL Slide 20 Proprietary to Wipro Ltd


 

Customer Requirement – delivered by Implementation Team

GB TRG MATERIAL Slide 21 Proprietary to Wipro Ltd


 

Actual Customer Requirement

GB TRG MATERIAL Slide 22 Proprietary to Wipro Ltd


 

Examples of Customer Responses on CTQs

 A Car Purchaser   A TV Purchaser 


 Good Acceleration • Flat Screen
 Spacious • Good Sound
  Affordable • NTSC / PAL Compatible
 Power Steering •  Affordable
 Loan Facility • Good After Sales Service

 A Caller to Help Desk  A Prospective Employee

• Quick Answering • Good Salary


• Courteous Response • Location Preference
• Quick Problem Resolution • Flexible Working Hours
• ESOPs
• Separate Cabin

GB TRG MATERIAL Slide 23 Proprietary to Wipro Ltd


 

How to Explore Customer CTQs

 Often, customer requirements are hazy

 Customer requirements must be understood clearly

 VOC is a technique to organize, analyze & profile the customer requirements


(collection of requirements is done through surveys / meetings)

VOC Table

GB TRG MATERIAL Slide 24 Proprietary to Wipro Ltd


 

VOC Data Source

REACTIVE SOURCES PROACTIVE SOURCES

Complaints Interviews

Problem or service hotlines Focus groups

Technical support calls Surveys

Customer service calls Comment cards

Claims, credits Sales visits/calls

Sales reporting Direct observation

Product return information Market research/monitoring

Warranty claims Benchmarking

Web page activity Quality scorecards

NPS survey outcomes can be Reactive & Proactive source

GB TRG MATERIAL Slide 25 Proprietary to Wipro Ltd


 

Define Internal CTQ / CBP

GB TRG MATERIAL Slide 26 Proprietary to Wipro Ltd


 

How to Arrive at Internal CTQs / CBPs


 Customer CTQs( needs) are often hazy & they must be converted into meaningful
internal goals that are assignable to functions

More structured methods & tools are available to convert Customer CTQs /
Business CTQs into internal CTQs / CBPs

 CTQ Drill-down

 Quality Function Deployment (QFD / House of Quality)

GB TRG MATERIAL Slide 27 Proprietary to Wipro Ltd


 

Example CTQ Drill Down

Improve
Profitability

Increase Offshore
Reducing
Realization Business
cost
or Billing rate Model

More
Manpower Travel & High End
Infrastr. cost New Geos Offshore
cost overheads Practices
component

Productivity Salary cost

Productivity (NLD) Projects were selected from the Business


CTQ of Profitability

GB TRG MATERIAL Slide 28 Proprietary to Wipro Ltd


 

One Example of A Typical CTQ Drill-down

 Example of On-time delivery CTQ

Total Units 168

Orders Fully Serviced 132 Orders Not Fully Serviced 36

A 36 B 47 C 31 D 18
A4 B 27 C1 D4

6 Late 31 late 8 late 7 Late

52 Defects 36 Defects

With the data support, team decided to take project in


Product B, Which is contributing to more than 70% defects

GB TRG MATERIAL Slide 29 Proprietary to Wipro Ltd


 

DMAIC
Define a Project

GB TRG MATERIAL Slide 30 Proprietary to Wipro Ltd


 

Theme Selection Matrix


 Theme selection matrix can be used to prioritize project themes coming from the
brainstorming exercise

 It is a structured & data-oriented prioritization exercise to select right project


  A scale of 1-9 is applied to evaluate multiple themes on four aspects. Final score is
arrived by multiplying the scores of each category
Rating Parameters for the themes (1-3-5-7-9)
Importance Importance
S.no. Selected Themes CTQ type to the to the Financial
internal E xternal benefi ts/ Final
customer  customer   A nnum E ffort   sco re

GB TRG MATERIAL Slide 31 Proprietary to Wipro Ltd


 

Theme Selection Matrix: Example


  A project team wants to select 1 project themes out of 4 by using the Theme selection
matrix
Rating Parameters for the themes (1-3-5-7-9)
Importance Importance
S.no. Selected Themes CTQ Financial
to the to the Final
benefits/ Effort 
internal External  s core
 A nnum
Customer  Customer 
Transition team productivity
1 Productivity
Improvement
NLD at small a/c ( less than 20
2 Productivity
resource )

NLD at large accounts ( more


3 Productivity
than 20 resources )
Improving Service Desk C-Sat/
4
performance ( CCOP Imp. ) Productivity

GB TRG MATERIAL Slide 32 Proprietary to Wipro Ltd


 

Scope the Project

GB TRG MATERIAL Slide 33 Proprietary to Wipro Ltd


 

What is Scoping?

 It’s an attempt to define what will be covered in the project deliverables

 Scoping sharpens the focus of the project team

 Sets the expectations right

 Types of Scoping

 Longitudinal Scoping

 Lateral Scoping

GB TRG MATERIAL Slide 34 Proprietary to Wipro Ltd


 

Longitudinal Scoping

 Longitudinal scoping is done on the length of the process

 e.g. – From the time a bug is assigned to the time it is submitted for fix

 e.g. – From the time of customer reporting the complaint till final satisfaction confirmation

 Mostly the ‘start’ & ‘end’ points are baton change points

  A macro as-is process map must be prepared to facilitate longitudinal scoping

GB TRG MATERIAL Slide 35 Proprietary to Wipro Ltd


 

SIPOC

Tool
P
Process

3
 S 
S I 1 2 5
O C I  

 O
 C 

Suppliers Inputs Outputs Customers


4

Process Boundary

GB TRG MATERIAL Slide 36 Proprietary to Wipro Ltd


 

Example of a Photocopying Process

GB TRG MATERIAL Slide 37 Proprietary to Wipro Ltd


 

Example - SIPOC
Process Name
Starting point: User sending a mail to Helpdesk
End point: Call logging in the Tool/Email Response to the Customer 

Suppliers Inputs Process Outputs Customers


Receipt of Mail
End User Mail
from User
Call allocation to
Wipro MIT Helpdesk Team the Helpdesk
Executive
Helpdesk • Acknowledgement
End User 
Executive Logs the Mail
Ticket On E-
Client – IT Dept IT infrastructure helpline*
HelpDesk sends
acknowledgement
to the Customer 

GB TRG MATERIAL Slide 38 Proprietary to Wipro Ltd


 

Process Mapping Nomenclature

Process Decision Data

Pre-defined Terminator 
Document
Process

Manual Manual
Delay
Operation Input

GB TRG MATERIAL Slide 39 Proprietary to Wipro Ltd


 

Lateral Scoping

 Lateral scoping is done on the breadth of the process

 e.g. – All despatches from North & South regions

 e.g. – Calls received during general shift

 One or more of the following are covered here:

 What all kinds of units the process will cover

 In what situations the process is valid

 What are the qualifiers for the transactions

 What functional domains does the process cover 

 In what geographical areas the process is valid

CTQ Drill down and pareto analysis will help in effective lateral scoping

GB TRG MATERIAL Slide 40 Proprietary to Wipro Ltd


 

Scoping Techniques

 Write inside the box what you think project covers


Tool
 Write outside the box what you think project excludes

Example for an ‘On time Despatch’ project


I  
n
 s 
Longitudinal i  
 d 
 e
Starts after receipt of PO from customer   Any transit delays -
 O
Ends at the despatch from factory  u
Product damages  t  
 s 
Lateral i  
 d 
Billing errors  e
Despatches from Mumbai plant
Non-availability of customer 
 All despatches during shift A
Despatch through transporter X

Project boundary

GB TRG MATERIAL Slide 41 Proprietary to Wipro Ltd


 

Quantify Benefits

GB TRG MATERIAL Slide 42 Proprietary to Wipro Ltd


 

Projection of Benefits

 Six Sigma has a strong focus on money

 Management buy-in is easier for tangible benefit projects

 Tangible benefits could be of various types

 Cost Reduction / Saving

 Increase in Sales / Revenue

 Enhanced productivity

 Enhanced measurable Customer Satisfaction

 Enhanced measurable Employee Satisfaction

GB TRG MATERIAL Slide 43 Proprietary to Wipro Ltd


 

DEFINE THE PROBLEM STATEMENT

GB TRG MATERIAL Slide 44 Proprietary to Wipro Ltd


 

Defining a Problem Statement

Our customers are angry with us and thus delay paying their bills.

In the last 3 months, 12% of our customers are late, by over 45 days in

paying their bills. This represents 20% of our outstanding receivables &

negatively affects our operating cash flow.

When
Consequence
What Magnitude

GB TRG MATERIAL Slide 45 Proprietary to Wipro Ltd


 

D M AIC
Establish
Performance
Parameters

GB TRG MATERIAL Slide 46 Proprietary to Wipro Ltd


 

Introduction - MEASURE

  A robust measurement system forms the basis of any Six Sigma project

  A measurement system has two characteristics

 Design of the measurement system

 Precision of the measurement system

GB TRG MATERIAL Slide 47 Proprietary to Wipro Ltd


 

Map Detailed As-is Process

GB TRG MATERIAL Slide 48 Proprietary to Wipro Ltd


 

What do you see here…any clarity?

GB TRG MATERIAL Slide 49 Proprietary to Wipro Ltd


 

See the Difference Now…

Recall..One
picture is
better than
1000 words

Process Mapping is a graphic display of steps & activities that constitute a process

GB TRG MATERIAL Slide 50 Proprietary to Wipro Ltd


 

Benefits of Process Mapping

 Simple & visible structure for thinking through a complex process

 Enables seeing the entire process as a team

 Enables seeing that changes are not made in a vacuum and will carry through,

affecting the entire process down the line

 Magnifies non value-added areas or steps

 Identifies cycle times of each step in the process

 Helps re-examine (if needed) the scope and charter of your project

GB TRG MATERIAL Slide 51 Proprietary to Wipro Ltd


 

Micro Process Map of a Manufacturing Process

despatch
as reject
no

yes   g/f sampling recording marking for finishing as


yes transfer to storage at installati guard
? application & properties ? next route per reqmnt. packing despatch/
 recoiling concerned customer on film
G/f  testing O.k as per cust. (coil, sheet, shipping
line end removal
reqmt. profile)

baking top
additional additional hot air  squeezing water  hot air  squeezin water baking primer 
as per coating additional additional ? no
inspection drying by rubber quenching drying g by as per  coating
cold air  cold air  thickness wf t=55-65 cold air  quenching cold air  end
temp-100 - roll temp=100 wf t-15-18 Paint
drying drying pmt-224 visco-58-65 drying (r.t.) rubber thickness drying
110 Deg C Deg C visc-30 sec peel off 
2 burner  roll -
yes

continuous squeezin hot squeezin cold (room squeezin wet squeezin chromating coating baking
hot air water hot air 
degreasing g by water g by g by scrubbing on back side as per g.p.
uncoiling of  temp) g by concn- 0.8 - drying drying
rinsing 30 wft thickness quenching complaint
coil concn-0.3-0.4 rubber rubber water rinsing rubber by scoth rubber 1.2 temp-100 temp -90-
temp=80 Deg C visco-30 -35 PMT -224 raising by
temp-80 Deg roll roll roll bright Ph-1.2-2.0 Deg C 100 Deg C
sec
customer 

START
2 stage
POINT testing of ph , concn. , squeezing
squeezing by
temp, by rubber
rubber roll visit to
of water , degreasing roll & CPC
customer for
and chromating assesment

replacement /
rework end

Make the process map aligned to your Project


objective, Don’t paste ISO process maps.

GB TRG MATERIAL Slide 52 Proprietary to Wipro Ltd


 

Another way of mapping processes- CFPM

 Teams can use this structure for processes that move across functions

Step
Function 1 Step 5
4

See Cycle time also.


Step 3 0.2, 0.1-
Average time & Range
0.5Hrs given
Function 2
Step 2 1.2, 1-
1.5Hrs

Step 1 Step 8 End


Function 3
4.5, 4-6
Hrs

Step 6 Step 7
Function 4

Process map is must in cycle time reduction projects


GB TRG MATERIAL Slide 53 Proprietary to Wipro Ltd
 

Points to Look For 

 The pain areas (identified at the time of project selection) must be within the
selected scope

 Guard against analyzing the process at this stage, just map as-it-is

 Do not map the process as you would like it to be

 Take care of Parallel & Sequential activities for Cycle time reduction projects

GB TRG MATERIAL Slide 54 Proprietary to Wipro Ltd


 

Define what to measure and how to measure

GB TRG MATERIAL Slide 55 Proprietary to Wipro Ltd


 

Why Collect Data?

 Improvement can only occur if we understand where we are & where to go, supported
by a measurement system that validates both situations

 Successful organizations have a common language to communicate-- Data

 Common language- Data, promotes objectivity in decision-making process

 Have you reached where you intended to? -- only data answers that question

 It’s rightly said…If you can’t Measure it, you can’t improve it.

GB TRG MATERIAL Slide 56 Proprietary to Wipro Ltd


 

Develop Operational Definition

  An Operational Definition is a precise description that tells how to get a value for the
characteristic you are trying to measure. It includes what something is and how to
measure it

 Purpose:
 Removes ambiguity  – common understanding of defect definition

 Identifies what to measure

 Identifies how to measure it

Aim is to have apple to apple comparison for


Baseline performance and improved performance.

GB TRG MATERIAL Slide 57 Proprietary to Wipro Ltd


 

Operational Definition - Examples

Try to Remove ambiguity from the statements

 I’m coming by 8 o’ clock….verify 8 am or pm

 I’m reaching Dammam by 8 o’ clock flight….verify 8 o’ clock is Arrival or Departure time

 I’m waiting for Doctor for so long…verify 5 minute or 5 Hrs

 Give me half bottle water---bottle may by 200ml to 20 Lt

 I’ve reduce patient’s waiting time…at which stage or what is the start & end point

 I’ve improve profitability…in which region/ which product

GB TRG MATERIAL Slide 58 Proprietary to Wipro Ltd


 

Operational Definition & Data collection plan

Operational Definition
Unit of What to Measure How to Measure
Measurement

Performance Operational Data source Sample Who will When will How will Other data that
measure (Y) definition and size collect the data be data be should be
location data collected collected collected at the
same time

GB TRG MATERIAL Slide 59 Proprietary to Wipro Ltd


 

Operation Definition - Example


Exp.: SLA Calculation at A/c level
 Objective: Why we need this/ Biz case

 Scope/ coverage: Reasons if not 100%

 Clarify what we are measuring: Uptime/ Response/ Resolution time, etc


 Is it aligned with the customer reqt (SLA/ Contract)

 Source of Data: IS System (Pure), Manual, Hybrid (IS System with manual
intervention )

 Sampling plan/ Freq of data collection

 Process owner

 Any stratification reqd/ recommended: SLA w.r.t. Skill calls, spare calls, EC Vs FE

 Challenges in authenticity of data: Like RE Call closure may not reflect 100%

GB TRG MATERIAL Slide 60 Proprietary to Wipro Ltd


 

Types of Data

 Discrete data

 Data that can take a limited number of values (Pass / Fail, OK / Not OK, W in / Loss)

 Examples

 Days in a week

 Number of ‘yes’ responses to a satisfaction survey

 Number of countries that play cricket

 Continuous Data

 Data that be expressed in either fractions or whole numbers

 Examples

 Temperature of the room  You need to be careful while selecting the


data type and you need to follow the same
 Exchange rate of a currency
approach in improve phase also.
 Yield of a process

 Height of a person

GB TRG MATERIAL Slide 61 Proprietary to Wipro Ltd


 

Which Type of Data is Preferable?

 Large sample sizes are required to measure higher Sigma multiples for discrete data

 Since continuous data measurements can be broken down, relatively smaller

samples are required for higher Sigma calculations

 Discrete data does not allow to understand the process variation…

8:30 AM 11:00 AM

A B C D

How G ood is G ood and How bad is B ad.

GB TRG MATERIAL Slide 62 Proprietary to Wipro Ltd


 

Design Sampling Plan for 


Establishing Process Baseline

GB TRG MATERIAL Slide 63 Proprietary to Wipro Ltd


 

What is Baseline?

 ‘Baseline’ refers to a reference point from where the improvement would be


measured

 For Base lining teams need to collect fresh ‘Samples’.

 Historical data may have measurement errors like operational definition issues,
which can lead to wrong projection of the Baseline

GB TRG MATERIAL Slide 64 Proprietary to Wipro Ltd


 

Introduction to Sampling

 We do sampling all the time

 Populations & Samples Tool

 Practical aspects – Cost & Time

 Sampling is done to study a representative portion of population

  Any term describing the characteristics of a sample is called statistic

  Any term describing the characteristics of a population is called parameter   S 


 a
m
 p
l  
i  
n
 g

Sample

Population

GB TRG MATERIAL Slide 65 Proprietary to Wipro Ltd


 

How Big a Sample?

Too Big: Too small:


• Requires too • Won’t do the job
many resources

Take BB Assistance for calculating Sample Size

GB TRG MATERIAL Slide 66 Proprietary to Wipro Ltd


 

D M AIC
Validate
Measurement System
for ‘Y’

GB TRG MATERIAL Slide 67 Proprietary to Wipro Ltd


 

Validate Measurement System for ‘Y’

In transactional environment a robust


Operational definition will ensure Good
measurement system
Use ITIL guidelines & Industry best
practices for arriving at right Operation
definition ( e.g. AHT, FCR etc )

Take BB help in designing & performing GR&R


Gage Repeatability & Reproducibility

GB TRG MATERIAL Slide 68 Proprietary to Wipro Ltd


 

DM  AIC
Establish
Process
Baseline

GB TRG MATERIAL Slide 69 Proprietary to Wipro Ltd


 

Compute Process Sigma Multiple Using


Collected Data

GB TRG MATERIAL Slide 70 Proprietary to Wipro Ltd


 

Six Sigma Metrics

Customer Specification / Unit / Defect Definition 1

Discrete Data Continuous Data

Defects

Defects per Unit Mean


(DPU) 2a 2b
Std. deviation
Defects per Million Opportunities
(DPMO)

Process Sigma Multiple - Z 3

GB TRG MATERIAL Slide 71 Proprietary to Wipro Ltd


 

Process Sigma Multiple for Discrete Data

GB TRG MATERIAL Slide 72 Proprietary to Wipro Ltd


 

Business Problem

  A project team wants to reduce the total waiting time taken in hospital (from reception
to discharge). Team has randomly collected the following data of last 3 weeks for the
waiting time for few patients/ customers :--

(Data given is in minutes)

USL decided by Management based on other hospitals study is decided at 60 Minutes max.

GB TRG MATERIAL Slide 73 Proprietary to Wipro Ltd


 

1 Customer Specification / Unit / Defect

 Unit:  Any customer/ patient coming for treatment 

 Customer Specifications: USL is 60 minutes

USL: Upper Specification Limit for a Performance Standard. Anything above this is a defect.

 Defect Definition:  Any customer whose total waiting time


exceeds 60 minutes

GB TRG MATERIAL Slide 74 Proprietary to Wipro Ltd


 

2a Discrete Data

 Let’s treat this data as discrete

 That means I would count the number of patients who had to wait more than 60
minutes

Customer 1 5 Customer 11 50 Customer 21 49


Customer 2 49 Customer 12 48 Customer 22 48
Customer 3 48 Customer 13 36 Customer 23 39
Customer 4 53 Customer 14 50 Customer 24 49
Customer 5 58 Customer 15 50 Customer 25 34
Customer 6 50 Customer 16 62 Customer 26 33
Customer 7 46 Customer 17 45 Customer 27 57
Customer 8 50 Customer 18 47 Customer 28 48
Customer 9 49 Customer 19 51 Customer 29 47
Customer 10 47 Customer 20 44 Customer 30 390

 There are only 2 defects in 30 units

GB TRG MATERIAL Slide 75 Proprietary to Wipro Ltd


 

2a Defects per Unit

Number of defects found at any check-point


DPU =
Number of units processed at that check-point

 So, DPU of the given data is = 2 / 30 = 0.067

GB TRG MATERIAL Slide 76 Proprietary to Wipro Ltd


 

3 Sigma Multiple Calculation – Discrete Data

 Every DPMO value relates to a particular Sigma Multiple or ZST value. In this case, this
process is working at 3.00 Sigma multiple
 The same can be calculated by Given Excel template also.
ZST ZST

GB TRG MATERIAL Slide 77 Proprietary to Wipro Ltd


 

Process Sigma Multiple for Continuous Data

GB TRG MATERIAL Slide 78 Proprietary to Wipro Ltd


 

2b Continuous Data

 Let’s treat the data of the waiting time data as Continuous and calculate Base Line
Sigma

 For calculating Baseline or Sigma Multiple ZST in continuous data, we need to


understand: Mean, s td deviation & s hape (Type of Di s tribution)
Customer 1 5 Customer 11 50 Customer 21 49
Customer 2 49 Customer 12 48 Customer 22 48
Customer 3 48 Customer 13 36 Customer 23 39
Customer 4 53 Customer 14 50 Customer 24 49
Customer 5 58 Customer 15 50 Customer 25 34
Customer 6 50 Customer 16 62 Customer 26 33
Customer 7 46 Customer 17 45 Customer 27 57
Customer 8 50 Customer 18 47 Customer 28 48
Customer 9 49 Customer 19 51 Customer 29 47
Customer 10 47 Customer 20 44 Customer 30 390

GB TRG MATERIAL Slide 79 Proprietary to Wipro Ltd


 

3 Sigma Multiple Calculation – Continuous Data

 In this case, Mean = 57.73 minutes

 Std dev : 63.54

 USL : 60 Minutes

 ZST can be calculated by the Excel Template.

 This process is working at 1.54 Sigma multiple ( ZST = 1.54, or DPMO = 484750).

 Can you notice the difference in Z ST & DPMO values by treating the same data in

different way. What is the message?

GB TRG MATERIAL Slide 80 Proprietary to Wipro Ltd


 

Introduction of Normal Distribution

GB TRG MATERIAL Slide 81 Proprietary to Wipro Ltd


 

Introduction to Normal Distribution

Normal Distribution with Figure 3.01


Mean =100
Standard Deviation = 10 1 unit
of
standard
deviation

- +
70 80 90 100 110 120 130

 It’s a Probability Distribution, illustrated as N ( µ, σ )

 Simply put, a probability distribution is a theoretical frequency distribution

 Higher frequency of values around the mean & lesser & lesser at values away from mean

 Continuous & symmetrical

 Tails asymptotic to X-axis

 Bell shaped

 Total area under the Normal curve = 1

GB TRG MATERIAL Slide 82 Proprietary to Wipro Ltd


 

Prediction based on Normal Distribution

Figure 3.02

- +
µ
- 1σ + 1σ

68.26%

- 2σ + 2σ
95.46%

- 3σ + 3σ
99.73%

- 4σ + 4σ
99.9937%
- 5σ + 5σ
99.99943%

- 6σ + 6σ
99.999998%

GB TRG MATERIAL Slide 83 Proprietary to Wipro Ltd


 

DM  AIC
Define
Performance
Goals

GB TRG MATERIAL Slide 84 Proprietary to Wipro Ltd


 

Improvement Paths in Process Sigma Multiple

 Mutually signed-off change in specification limits

 It’s not a process improvement

 Shifting the mean

 Reducing the variance

GB TRG MATERIAL Slide 85 Proprietary to Wipro Ltd


 

Benchmarking Exercise

GB TRG MATERIAL Slide 86 Proprietary to Wipro Ltd


 

Benchmarking

 Benchmarking is about looking at others for superior methods Tool

 Others may include suppliers, competitors, customers or even a different industry

 Benchmarking could be done both on means as well as ends



 e
n
Types of benchmarking  c 
 h 
m
 a
 Internal r 

i  
n
 Functional  g

 Competitive

GB TRG MATERIAL Slide 87 Proprietary to Wipro Ltd


 

Establish Process Improvement Goal p-value &


confidence band concept

GB TRG MATERIAL Slide 88 Proprietary to Wipro Ltd


 

Key Concepts
 If the existing process has to be improved, then the improvement goal should be
chosen only after proving statistically that it can be achieved only due to change,
& not by chance , I.e; the probability of achieving the goal with the current process
should be very low (generally <5%)
 In Minitab, Graphical summary command is used to identify the right target, that is
outside of 95% probability band of current data set.(Target can be set on mean as well
as std deviation)
Summary for June
 A nderson-Darling Norma lity Test
 A -Squared 351.69
P -V alue < 0.005

M ean 160.41
S tDev 483.73
 V ariance 233992.60
S kew ness
K urto sis
9.161
12 3. 073
 Any value, outside
N 1477

M inimum 1.77
this band will be a
1 st Q u art ile
M edian
2 3. 49
50.75 good target, as the
3 rd Q u ar ti le 9 2. 88
0 1200 2400 3600 4800 6000 7200 8400 M a xi mu m 8 35 4. 38 chances of getting
95% C onfidence Interval for Mean
135.72 185.10 it by current
95% C onfidence Interval for Median
46.95 55.05
process is <5%
95% C onfidence Interv al for StDev
95% Confidence Intervals
466.89 501.83
Mean

Median

50 75 100 125 150 175 200

GB TRG MATERIAL Slide 89 Proprietary to Wipro Ltd


 

DM  AIC
Identify
Variation
Sources

GB TRG MATERIAL Slide 90 Proprietary to Wipro Ltd


 

Means & Ends of a Process

Y = f ( X1, X2, X3……Xn )

Y X
Dependent Independent

Process Output Process Input / Step

Effect Cause

Symptom Problem

Monitor  Control

GB TRG MATERIAL Slide 91 Proprietary to Wipro Ltd


 

Generating & Prioritizing X’s

 Identifying & prioritizing X’s could be done using both non-statistical & statistical tools

 Identification tools include (non-statistical basis)


 Experience of process doers

 Brainstorming & Multi-voting Focus on identifying problem areas


 Process mapping

 Fishbone
Focus on identifying potential root causes

 Prioritization tools include

 Pareto Diagram

 Stratification

 Correlation (for a single X)

 Regression (for multiple X’s) Focus on prioritizing potential root causes

 Chi-square test

  ANOVA

 Failure Mode & Effect Analysis (FMEA)

GB TRG MATERIAL Slide 92 Proprietary to Wipro Ltd


 

Identification Tools

 Brainstorming & Multi-voting is a structured methodology to collect responses from a


group & arrive at a short-list

 Even though it provides a short-list, it’s not an effective prioritization tool because short-listing
is not done on any mathematical basis

 Use of Process mapping requires studying the micro as-is process mapped in step 2
earlier & walking through it

 Fishbone relates an ‘effect’ to its ‘cause’ by drawing a tree diagram

GB TRG MATERIAL Slide 93 Proprietary to Wipro Ltd


 

Points to Remember in Brainstorming

  All ideas are important, don’t out rightly reject any idea

 Participation should be ensured from all team members

 To ensure this, project teams could use the round-robin method of idea generation

 It’s advised to use the Black Belt as the facilitator here

GB TRG MATERIAL Slide 94 Proprietary to Wipro Ltd


 

Fishbone

  Also called “Cause & Effect’ or ‘Ishikawa’ diagram


Tool
 Focus of Fishbone is to arrive at the root causes of the problem areas identified
through multi-voting / process mapping

 It works on the principal of asking ‘why’ to each cause till you reach the ‘root cause’


i  
 s 

 b 
 o
n
 e

GB TRG MATERIAL Slide 95 Proprietary to Wipro Ltd


 

Characteristics of a Fishbone

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Characteristics of a Fishbone

• Search for the REAL


CAUSES of the problems
that you deal with.

GB TRG MATERIAL Slide 97 Proprietary to Wipro Ltd


 

How to Construct a Fishbone

 Review the problem statement / defect definition

 Brainstorm & identify possible causes

 Sort causes into reasonable clusters

 Choose the clusters & name them into big bones

 Check the logical flow of cause and effect

GB TRG MATERIAL Slide 98 Proprietary to Wipro Ltd


 

Fishbone Structure

How’s for 1st


Cause 1 Cause 2 House
Root-cause
221
Cause 11 Cause 21
Cause 22
Cause 12
Root-cause
222

Effect
Backbone
Cause 31

Cause 3

Big Bone Medium Bone

GB TRG MATERIAL Slide 99 Proprietary to Wipro Ltd


 

Fishbone Structure

How’s for 2nd


Cause 1 Cause 2 House
Root-cause
221
Cause 11 Cause 21
Cause 22
Cause 12
Root-cause
222

Effect
Backbone
Cause 31

Cause 3

Big Bone Medium Bone

GB TRG MATERIAL Slide 100 Proprietary to Wipro Ltd


 

Fishbone Structure

How’s for 3rd


Cause 1 Cause 2 House
Root-cause
221
Cause 11 Cause 21
Cause 22
Cause 12
Root-cause
222

Effect
Backbone
Cause 31

Cause 3

Big Bone Medium Bone

GB TRG MATERIAL Slide 101 Proprietary to Wipro Ltd


 

Fishbone Example

CRM malfunction Error in Listening

No
Lack of training maintenance
Printer error  on listening skills Problem with
CRM not saving the instrument
data properly Rough
handling

Wrong Customer
Backbone Details
No credit card verification

Root-cause 1
Foul order  No cross-check

Root-cause 2

Fishbone can be used in organizing the causes also.

GB TRG MATERIAL Slide 102 Proprietary to Wipro Ltd


 

Key Concepts

 It’s difficult to judge how many levels one needs to explore in a fishbone

 Sometimes project teams may hit the root-cause at multi-voting / process mapping
level, but they may do a further root-cause for the sake of it

 In such cases, it is always a good idea to see if there is further scope for exploring by
asking ‘why’

  Always remember that we are trying to identify controllable X’s , what can not
be controlled – can not be a root-cause

 One must be able to see the effect on ‘Y’ when values / levels of root-causes are
changed

GB TRG MATERIAL Slide 103 Proprietary to Wipro Ltd


 

Separate Vital Few from Trivial


Many for Further Screening

GB TRG MATERIAL Slide 104 Proprietary to Wipro Ltd


 

Prioritization Tools

 Some teams may do a multi-voting here, at the output of root-cause analysis

 Pareto diagram works on the 80:20 rule of 20% causes contributing to 80% of defects

 Co-relation & Regression help in identifying the movement of continuous ‘Y’ with
respect to continuous ‘X’

 ANOVA & Chi-square help in identifying the movement of continuous / discrete ‘Y’
with respect to discrete ‘X’

 Failure Mode & Effect Analysis (FMEA) identifies the process failure modes &
assigns a number to it that helps to prioritize the actionables

Success of all prioritization tools depends upon data collection

GB TRG MATERIAL Slide 105 Proprietary to Wipro Ltd


 

Pareto Diagram

  A graphical tool for ranking causes form most significant (Vital Few) to least significant (Trivial many).

 Based on Pareto principle, which was first defined by J.M Juran in 1950. Pareto principle was made Tool
after 19th century Italian economist V. Pareto (1897). Most effects come from relatively few causes.
 Also known as 80:20 Principle.

 Pareto diagram indicates which area should be taken up first in eliminating defects and improving
operations.

 Example:Suppose a person identifies multiple root-causes of reaching his office late.


Now he is not sure where to focus so that he reduces the occurrence of  P 
reaching late by minimum 50%.  a

 e
 t  
 o
 He has identified following root causes
 Woke up late
 Clothes not ready
 Breakfast not ready
 Bus not coming on time
 Traffic jam
 Bus waiting for other employees
 He collects data on how frequent each of the root cause is & constructs a Pareto

GB TRG MATERIAL Slide 106 Proprietary to Wipro Ltd


 

Pareto Diagram

Frequencies of root causes for reaching office late

70 100

60
80
50
      t       t
     n 60      n
    u 40      e
     o      c
     r
      C 30      e
40       P

20
20
10

0 0
  t   i m e  d  y   l   a t e  m  d  y  g
 a   t i  i n
  i n g   o n  
 o  t  r e a   u p  c  j  a
  i
  f
  f  
 o  
 t r e a   w
 
 c o m  t  e s
 o  h
 n   k e
  W o   T r a  a s  t 
  f
n   B u s
 s
 u  n o  t  
  l
 C   B r e
 
 a  k
  B
Count 25 18 15 6 5 2
Percent 35.2 25.4 21.1 8.5 7.0 2.8
Cum %  35.2 60.6 81.7 90.1 97.2 100.0

GB TRG MATERIAL Slide 107 Proprietary to Wipro Ltd


 

Other Prioritization tools

 So far, we have not used any statistical tool to prioritize X’s.

 Depending upon the data characteristics of Y & X, we can choose the appropriate tool

Correlation
Continuous &  ANOVA
Regression

 Y
Identify
opportunities for
Discrete converting ‘Y’ Chi-square
into a continuous
one or use FMEA

Continuous Discrete
X

GB TRG MATERIAL Slide 108 Proprietary to Wipro Ltd


 

Regression

 While correlation tells us only about the direction of movement, it does not
throw much light on degree of movement in one variable with respect to Tool
movement in another 

 Regression of ‘Y’ on ‘X’ results in a transfer function equation that can be used to
 predict the value of ‘Y’ for given values of ‘X’

R
Y = f ( X )  e
 g

 e
 s 
 ‘Y’ can be regressed on one or more X’s simultaneously  s 
i  
 o
 Simple linear regression is for one X n

 Multiple linear regression is for more than one X’s

GB TRG MATERIAL Slide 109 Proprietary to Wipro Ltd


 

Multiple Linear Regression (MLR)

 Multiple regression regresses ‘Y’ on more than one X’s simultaneously

 It is similar to Two-way ANOVA we have discussed in step 5, except for the difference
that X’s used in ANOVA were discrete

 The approach is similar & a linear multiple regression equation looks as follows:

 Y =  A + B1X1 + B2X2 + ………+ BnXn… + C

where Y = Dependent variable / output / response

X1 = First independent variable / input / predictor 


X2 = Second independent variable / input / predictor 
 A = Intercept of fitted line on Y axis
B1 & B2 = Regression coefficients / Slopes of the fitted plane on two axes
C = Error in the model

GB TRG MATERIAL Slide 110 Proprietary to Wipro Ltd


 

Multiple Regression Example

 Suppose we are trying to predict rent of an apartment based on the size of the
apartment & its distance from the main commercial area. We gather the following
information as below. If you are looking for a two-bedroom apartment 2 miles from the
main area, what rent should you expect to pay?

Y X1 X2

GB TRG MATERIAL Slide 111 Proprietary to Wipro Ltd


 

Multiple Regression Example

 Minitab gives the following output:

Regression Analysis
The regression equation is

Rent = 852 + 1381 * Rooms


Predictor Coef StDev T P

Constant 852 1146 0.74 0.511

Rooms 1381.0 259.5 5.32 0.013

Distance -5.4 142.1 -0.04 0.972

S = 975.3 R-Sq = 91.5% R-Sq(adj) = 85.8%

 Analysis of Variance

Source DF SS MS F P

Regression 2 30665301 15332650 16.12 0.025

Residual Error 3 2853449 951150

Total 5 33518750

 For a 2 bedroom apartment 2 miles away from main area, expected rent could be INR
3614 per month

GB TRG MATERIAL Slide 112 Proprietary to Wipro Ltd


 

ANOVA

  ANOVA is used to short-list potential discrete X’s for a continuous ‘Y’


Tool
 We can use one-way ANOVA & see the variation in ‘Y’ for one ‘X’ at a time

 We can use two-way ANOVA for more than one X


N
 O

GB TRG MATERIAL Slide 113 Proprietary to Wipro Ltd


 

ANOVA Example

  A team puts great emphasis on customer satisfaction. For some weeks, the ratings
seemed to suffer & the manager tried to identify the factors that could be causing this.
He chooses two of the potential discrete factors as ‘Team’ that handles the call & ‘Shift’
in terms of A & B. Which factor is vital?
Team Shift Rating

Desktop A 3.4
DC A 4.5
Desktop A 3.2
DC A 4.8
Desktop A 3.6
DC A 4.2
Desktop A 4.1
DC A 4.6
Desktop A 3.1
DC A 5
Desktop B 3.5
DC B 4.2
Desktop B 4.6
DC B 4.9
Desktop B 3.5
DC B 4.1
Desktop B 4.3
DC B 4.7
Desktop B 3.4
DC B 3.8

GB TRG MATERIAL Slide 114 Proprietary to Wipro Ltd


 

ANOVA Example
Two-way Analysis of Variance

 Analysis of Variance for Rating


Source DF SS MS F P

Team 1 3.281 3.281 17.38 0.001


Shift 1 0.013 0.013 0.07 0.800
Interaction 1 0.544 0.544 2.88 0.109
Error 16 3.020 0.189
Total 19 6.857

 Team that handles the call seems to be more important than shift

 In other words, two levels of the team, Desktop & DC, are significantly different in their average
ratings (between 'team' variation)

 However, error is quite high (within ‘team’ variation) which implies that there are other factors
contributing to variation in ratings

GB TRG MATERIAL Slide 115 Proprietary to Wipro Ltd


 

Failure Mode & Effect Analysis (FMEA)

 FMEA is a simple tool to prioritize the failure modes & actions


• Tool

•   

 By understanding why and how we fail, we can plan for success M



A

 It works on the belief that proactiveness saves time

 Typically, FMEA is applied on the output of root-cause analysis, & is a better tool for
focus / prioritization as compared to multi-voting

 We shall focus on Process FMEA (Design FMEA is used in designing products)

GB TRG MATERIAL Slide 116 Proprietary to Wipro Ltd


 

FMEA Concept & Output

Effect

Severity

Process / Product Failure Risk Action


Cause
Characteristics
Mode Priority Plan
Occurrence Number 

Control

Detectability

 Risk Priority Number (RPN) = S*O*D

 Severity, Occurrence & Detectability are measured on a scale of 1-10

GB TRG MATERIAL Slide 117 Proprietary to Wipro Ltd


 

FMEA Concept & Output

 Process / Product characteristics - Purpose of the product or Process

 Failure Mode - How can the product / process fail to function?

 Effects - Which effects are most severe to customer?

 Causes - Which causes are most likely to occur?

 Controls - Ability for current controls to detect causes?

 RPN - Which high risk cause we work on first?

  Action Plan - Recommended actions & responsibilities

GB TRG MATERIAL Slide 118 Proprietary to Wipro Ltd


 

Scales of ‘SOD’ - Severity 

 Severity is the seriousness of the effect of the failure mode on the customer 

 Rating Scale:

GB TRG MATERIAL Slide 119 Proprietary to Wipro Ltd


 

Scales of ‘SOD’ - Occurrence

 Occurrence is the probability that a specific cause will result in the particular failure mode

 Rating Scale:

GB TRG MATERIAL Slide 120 Proprietary to Wipro Ltd


 

Scales of ‘SOD’ - Detectability 

 Detectability is the probability that a particular cause will be detected

 Rating Scale:

GB TRG MATERIAL Slide 121 Proprietary to Wipro Ltd


 

FMEA Table

GB TRG MATERIAL Slide 122 Proprietary to Wipro Ltd


 

DMA C I
Explore
Potential
Causes

GB TRG MATERIAL Slide 123 Proprietary to Wipro Ltd


 

Explore Potential X’s for Causation

GB TRG MATERIAL Slide 124 Proprietary to Wipro Ltd


 

Recall Step 6: Creating a List of X’s & Prioritization

Brainstorming Regression, FMEA

FMEA
x1 x7 = 38%
x2 x6 = 27% Vital X’s
x3 x2 = 12%
x4
x5 Exploration of x9 = 4%
x6 the y-x x10= 4%
x7 relationship x5 = 2%
x8 x1
Trivial X’s σ error 
x9 x3
x10 x4
x11 x8 = 13%
x12 x11
x12
Fishbone

GB TRG MATERIAL Slide 125 Proprietary to Wipro Ltd


 

DMA C I
Design Counter-Measures

GB TRG MATERIAL Slide 126 Proprietary to Wipro Ltd


 

Counter-Measure Matrix

 Counter Measure Matrix is used to arrive at action to be taken on a root cause that
would lead to the desired result Tool

 If there are more than one counter-meas ure for a root cause, then the counter
meas ure is prioritized usi ng three parameters  C 
 o
 u
n
 Each counter-measure is given a rating on a scale of 1-7 (higher the better) & overall  t  
 e

-M
score is calculated by multiplying the 3 ratings, one with the best score is chosen
 e
 a
 s 
 u
 er 
M
 a
 t  

i  

GB TRG MATERIAL Slide 127 Proprietary to Wipro Ltd


 

Counter-Measure Matrix - Example

Cost optimisation levers


• CCOP
• Service Desk
• IR
• Automation

GB TRG MATERIAL Slide 128 Proprietary to Wipro Ltd


 

Map the New Process

GB TRG MATERIAL Slide 129 Proprietary to Wipro Ltd


 

DMAI C
Develop Control Mechanism

GB TRG MATERIAL Slide 130 Proprietary to Wipro Ltd


 

Controlling the X’s

 So far, we have identified the best settings for each of the vital ‘X’

 The key now is to ensure that the X’s don’t vary away from the targeted setting

 Process control is a crucial tool in ensuring that this Six Sigma project delivers lasting
benefits

 Maintaining X’s at their target level can be done in two ways


 Detection (reactive) Why was change not detected?

 Prevention (proactive) Why did / would change occur?

GB TRG MATERIAL Slide 131 Proprietary to Wipro Ltd


 

Correction Loop

Prevention
Prevention &
Detection

Mistake-Proofing Statistical Process


Control

GB TRG MATERIAL Slide 132 Proprietary to Wipro Ltd


 

Mistake-Proofing (Poka-Yoke)

 It is a technique to make errors difficult to happen, if not impossible


Tool
 Ground Rules of Mistake Proofing

 Intelligence does not depend upon hierarchy

 Target tasks that require constant alert / vigilance / memory M


i  
 s 
 t  
 a
 Look for cutting unproductive time to foster creativity k 
 e
-

 Defects are not acceptable, in whatsoever small number  r 
 o
 o
f  
i  
 It is best to make it impossible to do it wrong n
 g

GB TRG MATERIAL Slide 133 Proprietary to Wipro Ltd


 

Advantages of Mistake-Proofing

 Easy to accomplish without any formal training

 Removes repetitive tasks

 Fosters creativity & value-addition

 Ensures less defects

GB TRG MATERIAL Slide 134 Proprietary to Wipro Ltd


 

Mistake-Proofing Techniques - Examples

Technique Prevention Detection

Cameras that don’t click  Air-conditioners trip when


SHUTDOWN if the shutter is on detect slight over-heating

 ATM does not accept a Quality check at each


CONTROL card inserted wrongly point in the assembly

Car security system


WARNING alerting the driver that all Smoke detectors
doors are not closed

GB TRG MATERIAL Slide 135 Proprietary to Wipro Ltd


 

If Mistake-Proofing is Not Possible?

 Provide guidelines
 Check-lists
 SOP’s
 Templates

 Use visuals
 Color-codes
 Shapes

GB TRG MATERIAL Slide 136 Proprietary to Wipro Ltd


 

Statistical Process Control (SPC)

 SPC was developed by Walter A. Shewhart in 1924


Tool
 Historically, SPC has been used to monitor & control output ‘Y’

 S 
 In DMAIC, we apply SPC to control X’s (remember ‘Y’ is only monitored)  t  
 a
 t  
i  
 s 
 t  
i  
 c 
 a
 However, sometimes applying SPC to ‘Y’ can also be beneficial in detecting trends l  
 P 
 or 
 c 
  About SPC  e
 s 
 s 
  Aids visual monitoring & controlling  C 
 o
 Depends heavily on data collection n
 t  

 o
l  

GB TRG MATERIAL Slide 137 Proprietary to Wipro Ltd


 

Basics of Control Charts

 Control charts are useful for tracking process statistics over time and detecting the
presence of special causes

  A process is in control when most of the points fall within the bounds of the control
limits, and the points do not display any nonrandom patterns

GB TRG MATERIAL Slide 138 Proprietary to Wipro Ltd


 

Purpose of Control Limits

Special Cause Variation


UCL
  e
  s
  u
  a   n
  o
   C   i
   t
  n   i
  a CL
  o   r
  m   a
   V
  m
  o
   C
LCL

Special Cause Variation

Process Control’ is inherent to process characteristics as against ‘Process Capability’

which is measured as per outside targets & specifications

GB TRG MATERIAL Slide 139 Proprietary to Wipro Ltd


 

Purpose of Control Limits

0.135%
UCL = µ + 3σ

99.73% CL

LCL = µ - 3σ
0.135%
Out of control point

Control Limits define a probabilistic level


of occurrence of an ‘out of control’ point

GB TRG MATERIAL Slide 140 Proprietary to Wipro Ltd


 

Do Not Over-react to Change

  e
  m
   i
   t
UCL
  g
  n
   i Excellent Work Change the transporter??
   d
  a
  o
   L

LCL

Distinguish between Noise & Change

GB TRG MATERIAL Slide 141 Proprietary to Wipro Ltd


 

Top Eight Indications of an Out of Control Process

1. A single point outside 3σ control limits

2. Nine points in a row on the same side of the centerline

3. Six points in a row, all increasing or all decreasing

4. Fourteen points in a row, alternating up and down

5. Two out of three successive points more than 2σ on the same side of the
centerline

6. Four out of five successive points beyond 1σ on the same side of the centerline

7. Fifteen points in a row within 1σ on either side of center line

8. Eight points in a row with none between 1σ on either side of center line

GB TRG MATERIAL Slide 142 Proprietary to Wipro Ltd


 

Choosing An Appropriate Control Chart

Continuous Data

Individual Data Points Subgroups


Pulling one sample at fixed frequency Taking periodic grouped data

Variability of individual Variability of average


I & MR characteristics over time characteristics over time
X&R

GB TRG MATERIAL Slide 143 Proprietary to Wipro Ltd


 

Choosing An Appropriate Control Chart

Discrete Data

Defectives Defects

P-chart U - chart

Rest of the Control Charts are in the BB training Scope

GB TRG MATERIAL Slide 144 Proprietary to Wipro Ltd


 

Continuous data Control Charts

GB TRG MATERIAL Slide 145 Proprietary to Wipro Ltd


 

I & MR Control Chart

  Average Handle Time (AHT) by an agent is a vital ‘X’ for productivity. This is monitored
periodically to keep it within desired operating range.

 Data on AHT is collected over several hours


Hour AHT ( sec )

1 65

2 69

3 67

4 66

5 63

6 70

7 71

8 68

9 64

10 69

11 63
12 68

13 84

14 81
15 68

GB TRG MATERIAL Slide 146 Proprietary to Wipro Ltd


 

I & MR Control Chart : Minitab Output


 Minitab gives the following output:

I-MR
I &Chart of Temperature
MR Chart of AHT
1
5 UC L=82.93
80
  e
  u
   l
  a
   V
   l  _ 
  a 70
  u X=69.07
   d
   i
  v
   i
   d
  n
   I 60

LC L=55.20

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

UC L=17.04
16

  e
  g 12
  n
  a
   R
  g 8
  n
   i
  v
 __ 
  o MR=5.21
   M 4

0 LCL=0

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

GB TRG MATERIAL Slide 147 Proprietary to Wipro Ltd


 

Discrete data Control Charts

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P Control Chart

  A call center receiving calls will have to closed within specified SLA. Team has
collected data every hour to monitor process control

 Defective is defined as call not closed within SLA

GB TRG MATERIAL Slide 149 Proprietary to Wipro Ltd


 

P Control Chart : Minitab Output


 Minitab gives the following output:
P Chart of P defectives
0.4

0.3 UCL=0.2906

     n
     o
       i
      t
     r 0.2
     o
     p
     o
     r
      P

 _ 
0.1 P=0.0944

0.0 LCL=0

2 4 6 8 10 12 14 16 18 20 22 24
Sample
Tests performed with unequal sample sizes

GB TRG MATERIAL Slide 150 Proprietary to Wipro Ltd


 

Points to Remember in Control Charts

 Do not apply SPC tools to processes that are known to be out on control

 Do not compare control limits with specification limits

 Do not ignore ‘out-of-control’ signals if your ‘Y’ is meeting the specifications & ‘X’ is
meeting the operating limits

 Ensure that observations are independent of each other 

 It’s quite possible that ‘X’ is under control, but ‘Y’ is out-of-spec’s

GB TRG MATERIAL Slide 151 Proprietary to Wipro Ltd


 

Re-compute Process Baseline & Verify Against


Target

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Validating Process Improvements

Two-Sample T-Test and CI: Cost / Indent, Status (Control Phase)

Two-sample T for Cost / Indent


SE
Status N Mean StDev Mean
Before 7 300.7 47.6 18
Improved 7 154.1 61.6 23

Difference = mu (Before) - mu (Improved)


Estimate for difference: 146.7
95% lower bound for difference: 93.8
T-Test of difference = 0 (vs >): T-Value = 4.98 P-Value = 0.000 DF = 11

I-MR charts
( stage wise )

GB TRG MATERIAL Slide 153 Proprietary to Wipro Ltd


 

Develop Action Plan to Sustain


Improvement

GB TRG MATERIAL Slide 154 Proprietary to Wipro Ltd


 

How to Sustain Process Improvement

 Control Plan

 Training & Communication

 Project handovers with completed project dockets

 Database of vital X’s

 QFD / VOC

 FMEA / Fishbone

 Six Sigma Project Audits

 Process Owners

 SOP’s

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DMAIC SUMMARY: Problem Solving Flow

MEASURE  ANALYZE IMPROVE CONTROL

Business Statistical Statistical Business


Problem Problem Solution Solution

P R O J E C T

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Six Sigma resource in Wipro Intranet

 Q City : http://qcity.wipro.com:8080/hive/index.jsp

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Six Sigma resource in KM

 KM Link : http://knetsites.wipro.com/sites/1010/Pages/Default.aspx

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Process Excellence – Wipro Way


http://wiproway.wipro.com/default.asp

GB TRG MATERIAL Slide 159 Proprietary to Wipro Ltd


 

WI MQ – Mentor List

Name LOB Region Email id


Sachin Agarwal [ MBB ] Services Common HO - BLR [email protected]

Jyoti Prakash [ LBB ] Services Common HO - BLR [email protected]

Priya Mahadevan [ LBB ] MIT HO - BLR [email protected]

Rashmi Salgar [ BB ] ES & SI HO - BLR [email protected]

Sumathi Rajesh [ BB ] Regional MQ S2 [email protected]

Bhakti Gokhale [ BB ] Regional MQ West [email protected]

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Thank You

Improvement is a Journey…
and  Improvement is a Journey…
and 
Tog etherTog
Weether
Will
We Will

161
•Proprietary to Wipro Limited  © 2009 Wipro Ltd - Confidential

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