Muhammad Ali Yasir

Munzir Zafar
Faraz Fazil
“From 20,000 feet, six sigma has two primary
applications. First, it can be used to remove the variation
in routine, relatively simple, repetitive tasks. And
second, it can be used to make sure large, complex
projects go right the first time. ”
– Jack Welch, CEO General Electric
 Six Sigma
Applications

–Simple, repetitive – Complex Designs–

tasks –
- Activities that happen over
and over again
– Level of training and
education is manageable
-Territory of engineers &
scientists involved in endeavors
that takes years
– Sophisticated level of training
and statistical analysis
o The ability of a process to turn out a good product

o A relationship of product specifications to

manufacturing variability
o A relationship of product specifications to
manufacturing variability
μ

LSL Spec. width USL

Specifically,

conceptually as,

*Six sigma is achieved when the product specifications are at ±6σ of

the manufacturing process corresponding to Cp = 2
o Six Sigma is to improve Process Capability index

o But How?
 Increase product specification
OR
 Reducing manufacturing variability
Therefore, the Cp – formula can be rewritten as:

Or,
Concept Approval Design

M0 Build P0 Build P1 Build

Pilot Production
o Common language of all disciplines
o Analysis tool for every subassembly
o Guide in setting systems requirements
o Arbitrator between systems, design, and mfg
o Focus stick keeping the focus on parameters
o Auditor at each design stage
o Filter for supply chain
o Negotiator for technical customers
o Depending on past experiences for predicting
design effort and specifications allocation risks
o No quantitative design margin
o Unpredictable quality and costs
o Inaccurate budget allocation
o No basis of negotiation with design engineer
o Relying more on estimating the design function
effort based
o Design margin quantified
o Accurate prediction of future product quality
and cost methods
o Plan for investments in design and
manufacturing capabilities, the supply chain,
test strategies
o Use of six sigma analysis as the basis for
negotiations with design engineers.
 System Engineering

Key
Characteristics Process
Design

Design Process MFG Process

Quality Quality

Design Process MFG Process

DPU DPU

Module
Design Defects (Composite) Process Defects
Cpk
o Evaluation of design requirements
o Statistical analysis versus worst-case design
o Robust design avoiding unnecessary tight
tolerances or overdesigns
o Practicing the DFM rules
o Quantifiable quality of the design
o Evaluation of the quality of newly designed
products in manufacturing
o Begins with understanding current quality levels
o A plan to incrementally increase quality until the goal is
achieved
o A hierarchy of tools could be used at different
o Stages of quality
1. TQM (Total Quality Management)
2. SPC (Statistical Process Control)
3. DoE (Design of Experiments)
o TQM (Total Quality Management) tools and
techniques should already be in full utilization

o SQC (Statistical Quality Control)should also be

well implemented with wide use of control
charts in manufacturing and the supply chain
 Wave solder Process

Two Sided Mixed Technology PCB

The Cause-and-Effect Diagram
Results of Experiments
Level selection for lowest defects
Preheat A3 450°F
speed B1 3.0 RPM
height C3 6
pot temperature D3 490°F
“Once you understand the simple
maxim
‘variation is evil’
You are 60 percent of the way to becoming a six
sigma expert. The rest of the 40 percent is
”
getting the evil out.

– Jack Welch, CEO General Electric