1、,Supplier Six Sigma Integration,Communication Session,Synopsis of:,Supplier Six Sigma Integration Project,Vision Seagate suppliers embrace the Six Sigma culture to the extent that they use the Six Sigma methodology in making excellent decisions at all aspects of their daily operations. This will bes

2、t position them to continuously satisfy Delivery, Quality and Cost objectives.,Supplier Six Sigma Integration Project,Approach:,6 Tools Proliferation,6 Operational Framework,Integrated 6 Training,6 Performance Measurement,To proliferate the use of 6 tools in all key aspects of suppliers daily activi

3、ties.,To formulate the desired operational frameworks that facilitate, regulate and sustain the use of 6.,Design and develop excellent training program to facilitate 6 integration.,Implement a measurement system to measure and recognize suppliers Six Sigma effort.,Goal #1,Goal #2,Goal #3,Goal #4,Rol

4、lout Strategy,Supplier Six Sigma Integration,Goal #1: Six Sigma Tools Proliferation,Major Deliverable / Goal #1 To proliferate the use of Six Sigma tools in all key aspects of suppliers daily activities by Jan 2004.,Supplier Six Sigma Integration,Rollout Strategy,Goal #1: Six Sigma Tools Proliferati

5、on,(C) Six Sigma Projects Performance - (30 points),(A) QBR Performance - (30 points),(B) Strategic Business Partnership - (40 points),Task 1: Supplier Pre-Assessment To assess / classify suppliers into 3 proliferation groups by Jun 2001.,Category A “Dash” : 70 - 100 points Category B “Run” : 40 - 6

6、9 points Category C “Jog” : 0 - 39 points,Goal #1: Six Sigma Tools Proliferation,Supplier Classification Slips,Tasks 2 to 4: Proliferation of Six Sigma Tools To systematically integrate Six Sigma tools into daily operations of each supplier in 4 phases (Group 1 to 4 phases) by Jan 2004.,Goal #1: Six

7、 Sigma Tools Proliferation,3 Proliferation Groups of Suppliers Category A: average 4 months per phase Category B: average 5 months per phase Category C: average 7 months per phase Total 28 months for all targeted suppliers,Oct 2001,Jan 2003,Oct 2001,Jun 2003,Oct 2001,Jan 2004,Task 4,Task 3,Task 2,Go

8、al #1: Six Sigma Tools Proliferation,4 Groups of Six Sigma Tools Six Sigma tools are classified into 4 groups (Group 1 to 4 tools) according to ease of use and required depth of statistical knowledge. These are proliferated over 4 different phases of training and implementation.,G1 Phase,Supplier,G1

9、 Tools,G2 Tools,G3 Tools,G4 Tools,For example: Cause-and-Effect (fish-bone) diagram: Easy to understand and apply Group 1 tool Hypothesis testing, regression analysis and DOE: Require in-depth statistical knowledge Group 3 or 4 tools.,G2 Phase,G3 Phase,G4 Phase,Proliferation Matrix Group 1 to 4 tool

10、s are paired with a suppliers critical operations to form 4 Proliferation Matrices (see next 4 slides). For example, Group 1 tools will be integrated into a suppliers critical operations per Group 1 Proliferation Matrix.,Goal #1: Six Sigma Tools Proliferation,Group 1 Proliferation Matrix,Goal #1: Si

11、x Sigma Tools Proliferation,Group 2 Proliferation Matrix,Goal #1: Six Sigma Tools Proliferation,Group 3 Proliferation Matrix,Goal #1: Six Sigma Tools Proliferation,Group 4 Proliferation Matrix,Goal #1: Six Sigma Tools Proliferation,Goal #1: Six Sigma Tools Proliferation,Summarizing Tasks 2 to 4: The

12、 proliferation activities will be carried out per the following timelines:,Goal #1: Six Sigma Tools Proliferation,Six Sigma Tools Guidelines and Expectations Documents The Tools Guidelines and Expectations act as Help Documents to explain the “what, how leads to GB certification,Task 5 Train selecte

13、d suppliers on DFSS,Goal #3: Integrated Six Sigma Training,Overview,Goal #3: Integrated Six Sigma Training,On Modular Training .,Goal #3: Integrated Six Sigma Training,Task 3: Modular Training Syllabus (7 Modules, 4 Training Sessions),Modular Training Strategy,Goal #3: Integrated Six Sigma Training,

14、Progressively higher levels of learning & certification,Module 1 & 2,Module 3 & 4,Module 5,Module 6,Module 7 - Leads to Green Belt Certification,阿里巧巧 ,Modular Training Leading to Green Belt Suppliers will complete M1 to M6 modules on Six Sigma tools proliferation Suppliers may be invited to attend M

15、7 module which comprises additional Six Sigma tools and includes Six Sigma MAIC concept Upon completion of all 7 modules, trainees will be certified as Green Belts Note: At the end of each training session, trainees will need to pass a Statistical Tools Proficiency Test on basic concepts and fundame

16、ntals of statistics,Goal #3: Integrated Six Sigma Training,阿里巧巧 ,Modular Training Course Outline,Goal #3: Integrated Six Sigma Training,阿里巧巧 ,Goal #3: Integrated Six Sigma Training,Modular Training Cost Analysis,阿里巧巧 ,Cash In: Training Fund received from Suppliers,Cash Out: (Expenses incurred in eac

17、h training weeks),Modular Training Cash Flow Details,Goal #3: Integrated Six Sigma Training,阿里巧巧 ,Additional Information for Modular Training Training Fees: Total US$3,800 chargeable for training 1 supplier team Training fees need to be collected sequentially, i.e. US$950 reimbursement before each t

18、raining session begins Training package includes:,Goal #3: Integrated Six Sigma Training,Skills Training 4 training sessions comprising total of 7 modules Each training session = - 1 week classroom lectures - Includes hands-on practice, assessments & presentations,Amenities / Equipment Daily breakfa

19、st, lunch and 2 tea breaks Parking coupon, local phone call, stationery, training materials Graduation dinner,阿里巧巧 ,Additional Information for Modular Training Things that suppliers need to bring for training: Each supplier team needs to bring at least 2 notebook computers with licensed MS Office an

20、d Minitab installed by the supplier itself Each supplier needs to bring the following documents: Initial proliferation roadmaps drafted by supplier champion Company quality procedures SOPs, Process Instructions Latest F.A. package, etc Supplier is encouraged to bring additional material such as comm

21、odity specific initiatives, DPPM improvement plans, GR&R studies, etc.,Goal #3: Integrated Six Sigma Training,Per Application Areas of Proliferation Matrices,阿里巧巧 ,Modular Training Timeline - Overview,Goal #3: Integrated Six Sigma Training,Modular Training Timeline - Tentative Dates,Goal #3: Integra

22、ted Six Sigma Training,Goal #3: Integrated Six Sigma Training,On Additional Black Belt Training .,阿里巧巧 ,Task 4: Seagate Training for Additional Supplier Black Belts Training Fees: S$15K chargeable for each additional supplier Black Belt Training package includes: Full training fees need to be collec

23、ted before training begins,Goal #3: Integrated Six Sigma Training,Skills Training 4 phases (M,A,I,C) at 4 weeks per phase Each phase = - 1 week classroom lectures - 3 weeks hands-on practice at suppliers site,Amenities / Equipment Daily breakfast, lunch and 2 tea breaks Parking coupon, local phone c

24、all, stationery, training materials Reference books New notebook computer with licensed MS Office, Minitab & Visio Welcome and graduation dinners,阿里巧巧 ,External Training for Additional Supplier Black Belts Alternatively, suppliers may engage external bodies to train additional Black Belts. Some avai

25、lable consultants are: 1. Singapore Quality Institute (S$24,995) 4 one-week training sessions, each separated by 3 weeks of skills application 4 text books Excludes laptop computer and Minitab software 4 hours of teleconference support 2. Price Waterhouse Does not publish training costs, which will

26、be discussed with clients on an individual basis. Contact Master Black Belt: Mr Yang Bao Xiong, email: ,Goal #3: Integrated Six Sigma Training,阿里巧巧 ,Confidentiality and Concessions for Training by Seagate Confidentiality: Suppliers need to accept a Non-Disclosure Agreement on Black Belt course mater

27、ial All material with “Seagate Confidential” cannot be transferred or duplicated Concession: Modular Training If trainee withdraws from training half-way due to unforeseen circumstances, supplier may be allowed to send replacement candidate for same wave of Modular Training at no additional cost to

28、the supplier Additional Black Belt Training If Black Belt trainee withdraws from training half-way due to unforeseen circumstances, supplier may be allowed to send replacement candidate for next wave of Black Belt training at no additional cost to the supplier,Goal #3: Integrated Six Sigma Training,

29、Major Deliverable / Goal #4 Institute a measurement system by end of November 2001 to measure and recognize how well Six Sigma has been integrated into the suppliers operations.,Goal #4: Six Sigma Performance Measurements,Supplier Six Sigma Integration,Rollout Strategy,Task 2 Develop rating for Tool

30、s Proliferation performance,Supplier 6s Performance Measurements,Operations (Factory dppm, Product KPOV, Process KPOV),Management (6s Personnel, Projects Rollout, $Saving, etc.),Half Yearly Assessment of Suppliers by: 1. Product 2. Commodity,Annual 6s Scorecard,Best Overall Performance in Six Sigma,

31、Task 1 Formalize assess-ment criteria for management performance,Task 3 Identify KPOVs by commodity Formalize criteria to assess performance,Task 4 Develop recognition process for “Excellence in Six Sigma” and “Best Overall Performance in Six Sigma” Awards,Tools Proliferation (Progress of G1 to G4 P

32、hases),Goal #4: Six Sigma Performance Measurements,Overview,Task 1: Management Performance To measure suppliers management effort half-yearly on Six Sigma personnel deployment, project execution, projects performance, etc. using Six Sigma Management Performance Scorecard,Supplier 6s Performance Meas

33、urements,Management (6s Personnel, Projects Rollout, $Saving, etc.),Personnel Deployment BB : Employees ratio BB : GB ratio Champions, Executives,Project Execution BB projects per half year GB projects per half year,Projects Performance Realized vs projected $ Defect reduction vs goal,Cultural Integ

34、ration Integration Plan Training Roadmap,Goal #4: Six Sigma Performance Measurements,Personnel Deployment 1) Employee : BB ratio 2) GB : BB ratio 3) Supplier Executives, Champions, Finance Reps.,Project Execution 1) BB Projects per BB 2) GB Projects per GB,Projects Performance 1) Realized Savings vs

35、 Projected Savings 2) % Improvement towards Entitlement,Cultural Integration 1) Suppliers Roadmap for: - Tools Proliferation - Training 2) Statistical Software 3) Awareness Campaign: - Posters / Signs / Rewards,Goal #4: Six Sigma Performance Measurements,Task 2: Tools Proliferation Performance To me

36、asure suppliers effort in proliferating Six Sigma tools across its entire organization on a quarterly basis using Six Sigma Tools Proliferation Scorecard,Supplier 6s Performance Measurements,Tools Proliferation (Progress of G1 to G4 Phases),Example: Proliferation Phase Lapsed at Time of Assessment:

37、Group 1 Phase completely passed 2/3 of Group 2 Phase lapsed Group 3 and 4 Phases - not yet,Total Activities to be Completed All Group 1 activities 2/3 of Group 2 activities Group 3 & 4 activities - N.A.,Actual Activities Completed If all Group 1 activities completed - full score for Group 1 Phase If

38、 2/3 of Group 2 activities completed - full score for Group 2 Phase,Goal #4: Six Sigma Performance Measurements,Goal #4: Six Sigma Performance Measurements,2/3 of Phase period has passed at time of assessment,2/3 of Grp 2 Tools (Total 25) = 17,Specific KPOVs: Specific KPOVs are selected based on wha

39、t individual commodity leaders felt as important. LPC, Ping Test or Noise are some of the examples relating to this metric. Selected KPOVs must be applicable to all suppliers producing the same part. Assessment shown includes 3 specific KPOVs, but Comm. Leaders will decide actual number.,General KPO

40、V: DPPM - This metric include all form of defects this product could possibly have over the assessment period. Ttl defects or scrap (Qtr) Ttl Insertion or Tested,Refer to factory and customer rejects.,DPPM =,Task 3: Operations Performance To assess suppliers operations performance half-yearly in ter

41、ms of Six Sigma metrics on commodity-specific KPOVs and suppliers DPPM using Six Sigma Operations Performance Scorecard.,Goal #4: Six Sigma Performance Measurements,Process KPOVs Commodity specific: Eg. for Motor: Ping Test, Hub OD, Balance,Organization KPOV - Supplier In-house DPPM - Seagate Factor

42、y DPPM,Goal #4: Six Sigma Performance Measurements,Goal #4: Six Sigma Performance Measurements,Task 4: Annual Appraisal and Recognition To consolidate suppliers Six Sigma effort half-yearly and annually for appraisal and recognition with annual awards.,A. Half-Yearly Roll-up,Goal #4: Six Sigma Perfo

43、rmance Measurements,B. Annual Roll-up,# of Qualified Suppliers 20% of 6s Supplier Base?,Annual Shortlist of Qualified Suppliers with Effective Score 50%,“Excellence Award” given to Top 20% only,“Excellence Award” given to All Qualified Suppliers,“Best Performance in Six Sigma” Award given to Top Sup

44、plier,Like the pyramid, award symbolizes Strength Commitment Quality Endurance Rarity,Half-Yearly Six Sigma Assessment by SQE on Suppliers,Yes,No,Supplier Six Sigma Recognition Process,Goal #4: Six Sigma Performance Measurements,Top 20% (max.) of total Six Sigma supplier base will be recognized with

45、 the “Excellence in Six Sigma” Award if these nominees have achieved an effective score of 75% points or more in annual roll-up Top scoring supplier to be recognized with the “Best Overall Performance in Six Sigma” Award,So whats next after this Convention ?,阿里巧巧 ,Training Costs,Modular Training,Definitive Agreement