Six Sigma: Main Metrics and R Based Software for Training Purposes and Practical Industrial Quality Control
Abstract
Purpose: To clarify the different types of data likely to occur in any service or industrial process, the main applicable statistics for each type of data and the Six Sigma metrics that allow characterising and benchmarking organisational processes.
Methodology/Approach: A short reference to the statistical process control is carried out, from Shewhart’s works to Motorola’s achievements, followed by a short discussion of the use of Six Sigma tools as a part of today’s total quality approaches, and by a discussion of the continuous, attribute and counting data worlds and their main applications in process analysis. Because many quality professionals may have difficulties dealing with engineering perspectives, a review of main classic and Six Sigma process metrics is done with examples. Complementing discussions, four functions written in the R language are presented, which can deal with real organisational data, or can be used for training purposes.
Findings: The functions developed provide useful graphical displays and calculate all necessary metrics, having the ability to let the user provide theoretical values for training activities. Real and simulated case studies help understanding data worlds and respective Six Sigma metrics.
Research Limitation/implication: This paper reports an intentionally simple theoretical perspective of Six Sigma metrics and friendly software which is available to all interested professionals on request to the authors.
Originality/Value of paper: The paper presents clear definitions of main data types and metrics and is supported by a set of four new functions that can be used by any researcher with a minimum knowledge of the R software.References
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Stamatis, D., 2003. Six Sigma and beyond: statistics and probability. Boca Raton: St. Lucie Press (CRC Press LLC).
Thomas, A., Barton, R. and Chuke-Okafor, C., 2009. Applying lean Six Sigma in a small engineering company - A model for change. Journal of Manufacturing Technology Management, [e-journal] 20(1), pp.113-129. https://doi.org/10.1108/17410380910925433.
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Wadsworth, H., Stephens, K. and Godfrey, A., 2007. Modern Methods for Quality Control and Improvement. Chichester: Wiley.
Ward, S., Poling, S. and Clipp, P., 2008. Selecting Successful Six Sigma Projects. Quality, 47(10), pp.50-51.
Zgodavová, K., Bober, P., Sütöová, A., Lengyelová, K., 2019. Supporting sustainable entrepreneurship in injection molding of plastic parts by optimizing material consumption. Przemysł Chemiczny, [e-journal] 98(3), pp.1001-1009. http://doi.org/10.15199/62.2019.3.9.
Alves, M., 2011. Introdução à Programação em R. Porto: Publindústria, Edições Técnicas.
Antony, J. and Banuelas, R., 2002. Key ingredients for the effective implementation of Six Sigma program. Measuring Business Excellence, 6(4), pp.20-27.
Araújo, R., Santos, G., Costa, J. and Sá, J.C., 2019. The Quality Management System as a Driver of Organizational Culture: An Empirical Study in the Portuguese Textile Industry. Quality Innovation Prosperity Journal, [e-journal] 23(1), pp.1-24. http://dx.doi.org/10.12776/qip.v23i1.1132.
Barsalou, M., 2015. The ASQ Pochet Guide to Statistics for Six Sigma Black Belts. Milwaukee: ASQ Quality Press.
Bravi, L., Murmura, F. and Santos, G., 2017. Attitudes and Behaviours of Italian 3D Prosumer in the Era of Additive Manufacturing. Procédia Manufacturing, [e-journal] 13, pp.980-986. https://doi.org/10.1016/j.promfg.2017.09.095.
Brook, Q., 2006. Six Sigma and Minitab – A Complete Guide for all Six Sigma Practitioners. London: QSB Consulting, Ltd.
Cano, E., Moguerza, J. and Redchuk, A., 2012. Six Sigma with R: Statistical Engineering for Process Improvement. New York: Springer.
Cano, E., Moguerza, J., Prieto, M. and Redchuk, A., 2018. Six Sigma Tools for Quality Control and Improvement - Vignette for Package ‘SixSigma’. [pdf] The R Foundation. Available at: < https://cran.r-project.org/web/packages/SixSigma/ SixSigma.pdf > [Accessed February 2019].
Carvalho, F., Santos, G. and Gonçalves, J., 2018. The disclosure of information on Sustainable Development on the corporate website of the certified Portuguese organizations. International Journal of Quality Research, 12(1), pp.253-276.
Doiro, M., Fernández, J.F., Félix, M.J. and Santos, G., 2017. ERP - machining centre integration: a modular kitchen production case study. Procédia Manufacturing, [e-journal] 13, pp.1159-1166. https://doi.org/10.1016/j.promfg.2017.09.178.
Firat, S., Arioglu, M., Ersoy, E., Gök, S. and Ünal, E., 2017. A Six Sigma DMAIC Process for Supplier Performance Evaluation using AHP and Kano’s Model. International Journal of Business Analytics, [e-journal] 4(2), pp.37-61. https://doi.org/10.4018/IJBAN.2017040103.
Marques, C., Lopes, N., Santos, G., Delgado, I. and Delgado, P., 2018. Improving operator evaluation skills for defect classification using training strategy supported by attribute agreement analysis. Measurement, 119, pp. 129-141. https://doi.org/10.1016/j.measurement.2018.01.034.
Mitra, A., 2016. Fundamentals of Quality Control and Improvement. New Jersey: John Wiley & Sons.
Moosa, K. and Sajid, A., 2010. Critical analysis of Six Sigma implementation. Total Quality Management, 21(7), pp.745-759.
Paton, S., 2002. Juran: A Lifetime of Quality. Quality Digest, [online] Available at: < https://www.qualitydigest.com/aug02/articles/01_article.shtml > [Accessed May 2019].
Portaria 1198/91, 1991. Diário da Repúbica I – Série – B, 291, pp 6682-6684.
Pyzdek, T. and Keller, P., 2018. The Six Sigma Handbook. New York: McGraw-Hill.
R Core Team, 2019. R: A Language and Environment for Statistical Computing. Vienna: R Foundation for Statistical Computing.
Ribeiro, F., Santos, G., Rebelo, M. and Silva, R., 2017. Integrated Management Systems: trends for Portugal in the 2025 horizon. Procédia Manufacturing, [e-journal] 13, pp.1191-1198. https://doi.org/10.1016/j.promfg.2017.09.194.
Santos, D., Rebelo, M. and Santos, G., 2017. The Integration of certified Management Systems. Case Study – Organizations located at the district of Braga, Portugal. Procédia Manufacturing, [e-journal] 13, pp.964-971. https://doi.org/10.1016/j.promfg.2017.09.168.
Santos, G., Afonseca, J., Lopes, N., Félix, M. J., and Murmura, F., 2018. Critical success factors in the management of ideas as an essential component of innovation and business excellence. International Journal of Quality and Service Sciences, [e-journal] 3(3), pp.214-232. https://doi.org/10.1108/IJQSS-05-2017-0051.
Santos, G. and Barbosa, J., 2006. QUALIFOUND - a modular tool developed for Quality Improvement in Foundries. Journal of Manufacturing Technology Management, [e-journal] 17(3), pp.351-362. https://doi.org/10.1108/17410380610648308.
Santos, G. Bravi L. and Murmura, F., 2018. Fabrication laboratories: The development of new business models with new digital technologies. Journal of Manufacturing Technology Management, [e-journal] 29(8), pp.1332-1357. https://doi.org/10.1108/JMTM-03-2018-0072.
Santos, G. and Milán, A.L., 2013. Motivation and benefits of implementation and certification according ISO 9001 – The Portuguese experience. International Journal for Quality Research, [e-journal] 7(1), pp.71-86. https://doi.org/10.4314/ijest.v6i5.1.
Santos. G., Murmura, F. and Bravi, L., 2019. Developing a model of vendor rating to manage quality in the supply chain. International Journal of Quality and Service Sciences, [e-journal] 11(1), pp.34-52. https://doi.org/10.1108/IJQSS-06-2017-0058.
Stamatis, D., 2003. Six Sigma and beyond: statistics and probability. Boca Raton: St. Lucie Press (CRC Press LLC).
Thomas, A., Barton, R. and Chuke-Okafor, C., 2009. Applying lean Six Sigma in a small engineering company - A model for change. Journal of Manufacturing Technology Management, [e-journal] 20(1), pp.113-129. https://doi.org/10.1108/17410380910925433.
Tjahjono, B., Ball, P., Vitanov, V., Scorzafave, C., Nogueira, J., Calleja, J., Minguet, M., Narasimha, L., Rivas, A., Srivastava, A., Srivastava, S. and Yadav, A., 2010. Six Sigma: a literature review. International Journal of Lean Six Sigma, [e-journal] 1(3), pp.216-233. http://doi.org/10.1108/20401461011075017.
Wadsworth, H., Stephens, K. and Godfrey, A., 2007. Modern Methods for Quality Control and Improvement. Chichester: Wiley.
Ward, S., Poling, S. and Clipp, P., 2008. Selecting Successful Six Sigma Projects. Quality, 47(10), pp.50-51.
Zgodavová, K., Bober, P., Sütöová, A., Lengyelová, K., 2019. Supporting sustainable entrepreneurship in injection molding of plastic parts by optimizing material consumption. Przemysł Chemiczny, [e-journal] 98(3), pp.1001-1009. http://doi.org/10.15199/62.2019.3.9.
Authors
Costa, A. R., Barbosa, C., Santos, G., & Alves, M. R. (2019). Six Sigma: Main Metrics and R Based Software for Training Purposes and Practical Industrial Quality Control. Quality Innovation Prosperity, 23(2), 83–100. https://doi.org/10.12776/qip.v23i2.1278
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