Green Belt Course Structure

• Introduction to • Introduction to • Introduction to

variation Lean and Six Root Cause
• Understanding Sigma Analysis
Variation • Simple and • Data Driven

GAMMA
• Process robust problem Techniques

TAU
PSI

Stability solving • Process

• Process •Define the focused
Capability problem techniques
• Improving •Measure the • Validating root
process output correctly cause
stability and •Fix the
process problem
capability permanently at
the source

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Green Belt Workshop Module PSI -4

-4
Descriptive
Statistics- Process Stability
Discrete Data

Process
Capability

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Data Types

Attribute/Discrete Continuous
➢ Colors ➢ Dimensions
➢ Gender ➢ Profit
➢ Region ➢ Sales Revenue
➢ No. of tickets ➢ Handle Time
➢ No. of defects ➢ Lead Time
➢ No. of clicks ➢ Turn Around Time
➢ No. of items sold ➢ Weight
➢ Temperature

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Identify type of data
Minitab file: Descriptive Statistics

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Discrete data
Stat>Table>Tally Individual Variable…

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Discrete data
Graph>Bar Chart…

Chart of FTR
70

60

50
Percent

40

30

20

10

0
No Yes
FTR
Percent within all data.

© Benchmark Six Sigma. All Rights Reserved Page - 6

Green Belt Workshop Module PSI -4

-4
Descriptive
Statistics- Process Stability
Discrete Data

Process
Capability

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Control Charts for Discrete Data
This category of Control Chart displays data that result from counting the number of
occurrences or items in a single category of similar items or occurrences. These
“count” data may be expressed as pass/fail, yes/no, or presence/absence of a defect.
We often measure:
➢ Fraction non-conforming (p) and (np)
➢ Number of defects on product (c)
➢ Average number of defects (u)
Count or Classification
(Attribute Data)

Count Classification

Defects Defectives

Fixed Variable Fixed Variable

Sample Size Sample Size Sample Size Sample Size

C Chart U Chart NP Chart P Chart

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Which control chart should we use?
1. You work in a toy manufacturing company and your job is to inspect the
number of defective toy cars. You inspect 200 samples in each lot and then
decide to create a control chart to monitor the number of defectives.
Worksheet: Fast Track
2. Suppose you work in a plant that manufactures mobile screens. For each
lot, you pull some of the screens and do a visual inspection. If a screen has
scratch on the inside, you reject it. What chart should we use?
Worksheet: Mobile Screens
3. Suppose you work for a shirt manufacturer. Each shirt can contain a certain
number of puckered seams before it is rejected. For quality purposes, you
want to track the number of puckered seam per 100 shirts over a period of
several days.
Worksheet: Shirts
4. The Quality team at a BPO audits voice calls versus a checklist. Non-
conformance to any point on the checklist is considered defect. Use an
appropriate chart to check whether it indicates presence of a special cause.
Worksheet: Voice Calls
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NP Chart: Fast Track
Stat > Control Charts > Attributes Charts > NP

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NP Chart: Fast Track

NP Chart of Rejects
30
1

1
25

20 UCL=20.10
Sample Count

15

__
10 NP=10.6

LCL=1.10
0
1 4 7 10 13 16 19 22 25 28
Sample

© Benchmark Six Sigma. All Rights Reserved Page - 11

P Chart: Mobile Screens
Stat > Control Charts > Attributes Charts > P

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P Chart: Mobile Screens

P Chart of Rejects
0.30
1
UCL=0.2782

0.25

0.20
Proportion

_
P=0.1637
0.15

0.10

0.05 LCL=0.0492

1 3 5 7 9 11 13 15 17 19
Sample
Tests performed with unequal sample sizes

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C Chart: Shirts

Stat > Control Charts > Attributes Charts > C

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C Chart: Shirts

C Chart of Puckered Seam/100 Shirts

8
UCL=7.677

5
Sample Count

3 _
C=2.725

0 LCL=0

1 5 9 13 17 21 25 29 33 37
Sample

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U Chart: Voice Calls

Stat > Control Charts > Attributes Charts > U

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U Chart : Voice Calls

U Chart of Defects
0.35

0.30 UCL=0.3071

0.25
Sample Count Per Unit

0.20

_
0.15 U=0.1530

0.10

0.05

0.00 LCL=0

1 3 5 7 9 11 13 15 17 19 21
Sample
Tests performed with unequal sample sizes

© Benchmark Six Sigma. All Rights Reserved Page - 17

Green Belt Workshop Module PSI -4

-4
Descriptive
Statistics- Process Stability
Discrete Data

Process
Capability

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Process Capability- Discrete Data
Our objective is to evaluate current performance of Y (output)
and baseline it for comparison post improvement. We may
choose to compute Sigma level or any of the following baseline
metrics (for discrete data)

Data Method
Defects (Discrete) DPMO – Defects Per Million Opportunities
OFE known
Defects (Discrete) DPU – Defects Per Unit
OFE is difficult to ascertain
Defectives (Discrete) Yield (%) / Defective %

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DPMO method for Attribute Data
Situation 1: Sample Size, Defects, OFE known

Example: Phone calls are recorded at a call center and later evaluated. A
sample of 100 calls are heard by the quality representatives and evaluated
based on a Call Quality Checklist. There are 10 Opportunities for error in each
call. 150 defects were observed in the sample of 100 calls. What is DPMO?

Samples inspected = 100 DPO = 150/1000 = 0.15

Output
Inputs

Defects=150 DPMO = 150000

OFE=10 Zoverall = 1.04
TOFE= 10*100=1000

OFE Opportunities for error per unit = number of characteristics inspected per unit
DPO Defects per Opportunity

DPMO Defects per million Opportunity

Zoverall Sigma Level Overall

© Benchmark Six Sigma. All Rights Reserved Page - 20

DPMO method for Discrete Data
https://www.benchmarksixsigma.com/calculators/

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DPU method for Discrete Data
Situation 2: Sample Size, Defects, OFE is difficult to ascertain

Example: 200 shirts were inspected for puckered seams

(considered as defects). One shirt can have more than one
puckered seam. We observed 200 defects. What is DPU?

Units inspected = 200 DPU= 200/200 = 1

Output
Inputs

Zoverall = -0.34
Defects = 200

DPU Defects per Unit

Zoverall Sigma Level Overall

© Benchmark Six Sigma. All Rights Reserved Page - 22

DPU method for Discrete Data
https://www.benchmarksixsigma.com/calculators/

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Yield method for Discrete Data
Situation 3: Sample Size, Defectives

Example: 1000 samples were inspected. 50 were found to be defective. What

is the Yield?

Units inspected = 1000 Yield= 950/1000 = 95%

Output
Inputs

Defectives = 50 Zoverall = 1.64

Non-Defectives= 1000-50=950

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Yield method for Discrete Data
https://www.benchmarksixsigma.com/calculators/

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Sigma Level for Attribute Data
Exercise 1: Product catalogues displayed on the website of an e-commerce
platform are being inspected to check whether the following attributes are
correct: 1.Item model number; 2.Brand name; 3.Price; 4.Image; 5.
Description. 200 SKU’s were inspected, and 5 defects were observed. Use the
appropriate metric to baseline the process

Exercise 2: 2000 lines of delivered code was inspected. 100 errors were
found. Use the appropriate metric to baseline the process

Exercise 3: Loan files are being evaluated at a bank. A sample of 200 files was
checked by the quality representatives and evaluated based on a Quality
Checklist. There are 8 Opportunities for error in each file. 50 defects were
observed in the sample of 200 files. Use the appropriate metric to baseline
the process

Exercise 4: 800 pressure valves were inspected. 40 were defective. Use the
appropriate metric to baseline the process
© Benchmark Six Sigma. All Rights Reserved Page - 26
Yield Concepts
✓ Yield
✓ It is the first-time right percentage

✓ Kinds of Yield
✓ First Time Yield (FTY)
✓ Used to determine the quality level of individual sub process

✓ Rolled Throughput Yield

✓ Shows quality of entire process. Obtained by multiplying individual FTY’s of
sub processes

© Benchmark Six Sigma. All Rights Reserved Page - 27

 Sigma level for Yield
Consider the following process.

Filling Loan Completeness Entering Customer Credit

Application of Application Application data check
Yield of 100% Yield of 92.5% Yield of 93.0% Yield of 94.4%

RTY = 1.00 × 0.925 × 0.930 × 0.944 = 0.8121 = 81.21 %

Submit Confirmation
Requisition
requisition Purchase sent to
Fill out entered to
92% requisition 95% to
purchase
85% the 95% order sent
to supplier
99% requisition
co-
computer
dept coordinator

RTY=

RTY Rolled Throughput Yield

FTY First Time Yield

© Benchmark Six Sigma. All Rights Reserved Page - 28

Exercise 1
Dough Prep Apply sauce Add cheese Add toppings Bake

FTY of Each Sub-process (The steps are sequential)

87% 90% 96% 95% 100%

You own a Pizza shop. Lately you have observed lot of wastage in various
steps of the process leading to high expense on raw materials. To resolve the
issue you have declared that employees will get a bonus at the end of the
quarter only if the overall wastage of the process is less than 30%. The data
of the FTY of each sub process (at the end of the quarter) is given above. Will
you dispense the bonus?

© Benchmark Six Sigma. All Rights Reserved Page - 29

Exercise 2

FTY of 92.5%

Waste 7.5% FTY of 93%

FTY of 94.4%
Waste 7%

Waste 5.6%

© Benchmark Six Sigma. All Rights Reserved Page - 30

 Glossary (1/3)
A D H M
•Accuracy •Defectives •Handoffs •Mean Improvement
•Attribute Agreement Analysis •Defects •Hypothesis Testing 1 •Measurement System Analysis
•DMAIC 1 •Hypothesis Testing 2 (MSA)
B •DMAIC 2 •Hypothesis Testing 3 •Median
•Balanced Scorecard 1 •DMAIC 3 •Hypothesis Testing 4 •Metrics
•Balanced Scorecard 2 •DMAIC 4 •Mistake Proofing 1
•Baseline •DMAIC 5 I •Mistake Proofing 2
•Brainstorming 1 •DPMO 1 •IDOV •Mistake Proofing 3
•Brainstorming 2 •DPMO 2 •Inter Quartile Range
•Business Excellence •Inventory N
E •Ishikawa Diagram •Net Promoter Score (NPS)
C •Effective/Efficient •Nominal Group Technique (NGT)
•Checksheet •Efficiency J •Non Value Adding (NVA)-1
•Control Plan 1 •Evolution of Six Sigma •Jidoka •Non Value Adding (NVA)-2
•Control Plan 2 •Excellence •Normal Distribution
•Correction K •Null Hypothesis
•Corrective Action F •Kaizen 1
•COPQ, Cost of Poor Quality 1 •5S •Kaizen 2 O
•COPQ, Cost of Poor Quality 2 •False Alert, Missed Alarm •Kanban 1 •Observation
•Creativity & Innovation 1 •Fishbone Diagram •Kanban 2 •One Factor At a Time (OFAT)
•Creativity & Innovation 2 •First Time Yield •Operational Definition
•CTQ •FMEA 1 L •Operational Excellence
•Customer •FMEA 2 •Lead Time •Outlier
•Customer Satisfaction (CSAT) •Force-Field Analysis •Lean
•Lean Six Sigma
G •Lessons Learned
•Green Belt
•Groupthink
•Guide to Hypothesis Test

© Benchmark Six Sigma. All Rights Reserved Page - 31

 Glossary (2/3)
P Q S cont… T
•Pareto Chart 1 •Quality Assurance •SCAMPER •TIMWOOD
•Pareto Chart 2 •Quality Control •Scatter Plot •Tollgate Reviews 1
•Personal Excellence •Quality Costs •Scope Creep •Tollgate Reviews 2
•PFMEA 1 •Quick Win •Seven Wastes of Lean •Trends
•PFMEA 2 •Severity Ranking •Tribal Knowledge
•Pilot R •Sigma Level-1 •Type I Error
•Point of Use Inventory •RACI •Sigma Level-2 •Type II Error
•Poka-yoke •Range •Simpson's Paradox
•Power of a test •Regression Analysis-1 •Single Piece Flow U
•Pre-Control Chart •Regression Analysis-2 •SIPOC •Unbiased Sampling Error
•Preventive Action •Reporting Bias •Six Sigma
•Process •Resolution •Special Cause V
•Process Excellence •Rework •Special Process •Validation
•Process Input/Process Output •Risk Priority Number (RPN) •Special Requirement •Value Adding (VA)-1
•Process Mapping 1 •Root Cause •Specification Limit •Value Adding (VA)-2
•Process Mapping 2 •Root Cause Analysis 1 •Sponsor •Verification
•Process Stability •Root Cause Analysis 2 •Spread •Variance
•Productivity •Rolled Throughput Yield •Stability •Variation Reduction
•Project •R-Squared •Stable Process •Visual Control
•Prototype •Run Chart •Stakeholder •VOB
•Pull System 1 •Stakeholder Engagement •VOC-1
•Pull System 2 S •Standard Deviation •VOC-2
•Push System 1 •6 Big Losses •Statistical Significance •VOC-3
•Push System 2 •6S •Stop Gap Arrangement
•P-value •Sample •Stop The Line
•Sample Size-1 •Stratified Sampling
•Sample Size-2 •Swim Lane Mapping
•Sample Size-3
•Sampling
•Sampling Error
© Benchmark Six Sigma. All Rights Reserved Page - 32
 Glossary (3/3)
W
•Wastes-1
•Wastes-2
•Waste Elimination
•Weighted Pareto
•WIFM
•WORMPIT

X
•X
•Xbar-R

Y
•Y
•Y=f(X)
•Yield-1
•Yield-2

Z
•Zero Defect

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