Six Sigma Templates Archives

DMAIC Tools | DMAIC Template | Six Sigma Methodologies | 30+ Free Tools

07/04/202609/04/2024 by TECHIEQUALITY

DMAIC Tools | DMAIC Template | Six Sigma Methodologies | 20+ Free Tools

Hello readers! Today we are going to discuss an important topic on various DMAIC tools, Six Sigma methodologies, and the DMAIC template and its usage. Six Sigma is a very popular methodology that has been using in manufacturing industries for continuous improvement. A set of methodologies and various tools are used to improve the processes by optimizing efficiency, eliminating waste, reducing defects, minimizing variation, reducing errors, and increasing quality, etc. The main objectives of Six Sigma projects are to enhance the Sigma level and to reduce or minimize the DPMO (Defects per million opportunities).

What are the Six Sigma Belt Levels?

As we know that there are various belts in Six Sigma certifications, for example, master black belts, black belts, green belts, yellow belts, white belts, etc. Let’s understand the details of all belts;

six sigma belts level — Six Sigma Belts Level

White Belt:

This is the first level of six sigma certification. During white belt certification, you can learn the overview of the entire six sigma course. This six sigma course mainly emphasizes the basic concept of six sigma, fundamental methodology, terminology, etc. the course time periods may depend on the course providers once you are certified in the course you can easily understand the basic of Six Sigma and can work as problem-solving team that supports the overall projects teams. Many times people are confused about choosing the six sigma certification belt level. But I hope after reading all the Six Sigma belt levels, you can easily choose the course for yourself.

Yellow Belt:

Don’t confuse yourself when hearing about different types of belts. Different types of belts are classified according to the different levels of course like basic to advanced, roles of the certificate holder, level of project, knowledge level, etc. so according to your understanding of Six Sigma you can choose the certification course. The yellow belt is the second level of the certification course. The yellow belt certificate holder can participate as a project team member. And can review the process improvement that supports the project and review the six sigma process. However, the yellow belt is not adequate to empower certificate holders to lead a six sigma project.

Green Belt:

Through the Green Belt, a GB-certified holder may have with proper knowledge and understanding of Six Sigma methodology, application of tools, etc. As a GB certified holder, you can lead the GB Six Sigma project or teams. In the GB project, you can take part as a team leader or member of the GB six sigma project with strategy implementation, methodology application, problem-solving, decision-making, etc. You can help with the black belt project for data collection and analysis.

Black Belt:

The black belt certified holder’s primary roles are process improvement, variation reduction, quality enhancement, DPMO reduction, and Sigma level enhancement by applying the six sigma methodology and concept. This is the advanced level, of course, compared to the green belt. BB certificate holder leads the project, trains and coaches the project teams as well.

Master Black Belt:

MBB is the high point of the six sigma course. A master black belt certificate holder trains and coaches the black belt and green belt holder. Your role is to make a six sigma strategy and implement an advanced level. Act as a six sigma technologist and give the strategic direction to the next level in your organization. You play a vital role as an expert in providing leadership, facilitation, methodology application, and strategic direction.

Now, we will discuss on some common numerical terminology of Six Sigma which is frequently used in projects like DPU, DPO, DPMO, DPPM, Cp, Cpk, RPN, PN, Gauge R&R, Sigma level, P value, etc. sigma level you can choose from the sigma level table w.r.t DPMO value or you can calculate the value on excel as well.

DPMO, DPU, DPO, DPPM:

DPMO (Defects per million opportunities):

Before starting the DPMO calculation and concept, we will be understanding what is defects and defective items with the manufacturing practical example. Let’s consider a process control inspector doing the inspection in the production line and he booked some non-conforming items. He has recorded 5 non-conforming items and rejected those due to finding the following defects in items

Items	Defects
Item-1	Defect-1, defect-2, defect-3
Item-2	defect-3
Item-3	defect-2, defect-3
Item-4	Defect-1, defect-2
Item-5	Defect-4

Now, you can see in the above table we have recorded the 5 items and their defects. Every 5 items have a defect, so all 5 items are defective items or non-conforming items. If you look closely at the above table then you can find one thing that each item has one or more than one defect in a single unit. So, for example, item-1 is a defective product and having 3 defects. I hope the concept of defective vs defects is now understood. So, let’s arrange the above data table for easy understanding.

Items	Defect-1	Defect-2	Defect-3	Defect-4
Item-1	x	x	x
Item-2			x
Item-3		x	x
Item-4	x	x
Item-5				x
Total Defects =	2	3	3	1

The total defects of the 5 items are 9. (2+3+3+1). And the total number of defective items is 5.

Now we will calculate the value of DPU, DPO, DPMO, and DPPM.

In the above table, we found the following data as;

Total Defects = 9

Total Defective unit = 5

Defects opportunity per unit = 4

Total Units (for example) = 100 nos.

Total defects opportunities = 400 (4 x 100)

DPU (Defects per unit):

DPU Formula = Total number of Defects / Total units

DPU Calculation: DPU = 9/100 = 0.09

Defects Per Opportunity- DPO:

DPO Formula = Total number of defects/ (number of units x defects opportunity per unit)

= Total number of defects/ Total defects opportunities

= 9/ 400 = 0.0225 = 0.023

(Defects per million opportunities) DPMO:

DPMO Formula =

{Total number of defects/ (number of units x defects opportunity per unit)} x 1000000

= (Total number of defects/ Total defects opportunities) x 1000000

DPMO Calculation:

= (9/400) x 1000000

= 22500

(Defective Parts Per Million) DPPM:

DPPM Formula = (Total Defective parts / Total parts) x 1000000

DPPM calculation: (5 / 100) x 1000000

= 50000

According to the above data set the DPU, DPO, DPMO, and DPPM calculated values are given below table.

Date Set:

Total Defects = 9

Total Defective unit = 5

Defects opportunity per unit = 4

Total Units (for example) = 100 nos.

Total defects opportunities = 400 (4 x 100)

Values:

DPU (Defects per unit): 0.09

DPO (Defects Per Opportunity): 0.023

DPMO (Defects per million opportunities):22500

DPPM (Defective Parts Per Million) : 50000

Excel calculator:

If you are interested to download the Excel DPMO calculator and DPPM calculator then download them from the below link.

Download Excel DPMO & DPPM Calculator

How to use Excel DPMO & DPPM Calculator?

It’s very simple to use our excel template just download the excel calculator and then follow the below steps.

Step-1: Download the excel DPMO and DPPM calculator from the above given link.

Step-2: Enter the value only on the yellow highlighted box.

Step-3: The DPU, DPO, DPMO, and DPPM values will be calculated automatically.

Manufacturing Example:

Let’s consider a company manufacturing automobile parts. And they are producing x nos of parts on a monthly basis but facing a huge rejection in the production line at the blanking and piercing operation process. so, it has been decided in the quality meetings for improvement projects to reduce the rejection% and improve the variation. So, for the improvement project, the Line QA engineer collected the following data for the calculation of DPU, DPO, DPMO, and DPPM for project input. Data are given in below table;

Total Defects = 2763

Total Defective unit = 921

Defects opportunity per unit = 6

Total parts produced = 6100407

Total defects opportunities = 3,66,02,442 (6100407 x 6)

Without wasting my time, I’m going to calculate the value by using the above excel template. And the calculated value is given below.

I would request to all my readers, who are currently reading this article try to calculate the DPMO and DPPM values manually by apply the above formula and match with the excel calculator value.

Regarding the process capability calculation we have already uploaded the article you can read our article on How to measure process capability (Cp & Cpk)? Download Excel Template.

Process Capability Analysis |Cp & Cpk Calculation Excel Sheet with Example

Defectives vs Defects:

Let us understand the difference between Defect and Defective with the help of the above example. As you can see in the above image one product having two nonconforming quality characteristics which do not meet the standard or customer requirement, which is called a defect, and the whole product is called a defective product because having two defects. If you would like to know the total defective product and total defects in the above example, then we can easily say that the total defective product is 1 and the total defects are 2. Now I hope you understand the difference between defective and defects.

Six Sigma Methodologies:

There are many methodologies used in six sigma projects but the popular methodology is DMAIC (Define, Measure, Analyze, Improve and Control). Similarly, in the design of the Six Sigma project, the popular methodology is used as DMADV (Define, Measure, Analyze, Design, and Validate). However in Lean Six Sigma, both lean tools and DMAIC methodology are used.

DMAIC Tools & DMAIC Template

DMAIC methodology is a very popular mythology that is used in six sigma projects. The DMAIC methodology consists of 5 phases i.e. Define Phase, Measure Phase, analyze Phase, Improve Phase, and Control Phase. We have already published common and popular DMAIC tools, DMAIC templates, and formats. But following DMAIC tools are listed below;

DMAIC Tools, Template, and Format:

Project Charter.
SIPOC
VOC / CTQ / VOS
Data Collection Template.
FMEA
MSA (Gauge R&R, Attribute type MSA).
Cp and Cpk.
Control Chart (e.g. X bar & R chart, P-chart, C- chart, etc.)
Control Plan or QAP
Hypothesis testing tools.
Why-Why Analysis.
5W1H.
5W2H
Lean tools
DPMO calculation template.
Sigma-level calculation template
Pareto Chart
Histogram.
Scatter
Cause & Effect Diagram
Paired comparison
Logistic regression
Poisson regression
2-P test
Chi-square test
Simple regression.
Correlation
T-test
Z-test
F-test
Annova Test., etc.

If you would like to download the free templates and formats then click on DOWNLOAD Free Templates.

QA/QC/TQM/Lean/Six Sigma Templates or Format:

DMAIC Tools | DMAIC Template | Six Sigma Methodologies | 30+ Free Tools

Six Sigma Project Charter Template

DPMO Calculation, Formula, Template & Manufacturing Example

Process Flow Diagram Template | Examples |Symbols |PFD

P Chart Excel Template | Formula |Example | Control Chart | Calculation

C Chart Excel Template | Formula | Example | Calculation

SIPOC Template | SIPOC Diagram Example of Manufacturing & Service Industry

Scatter Diagram Template | Industrial Example | Download Excel Format

4M Checklist Template | Free Download Format

3MU Check sheet | Details of MURA, MURI & MUDA | Download

Dispersion Analysis Cause & Effect Diagram Template |Download Excel Format

5W1H Analysis Example |Download Template

5W2H Analysis Example |Download 5W2H Format

Fault tree analysis template | Download format free…

Process Performance (Pp) & Ppk Excel Template |DOWNLOAD

Histogram Template with example | Download

SWOT Analysis Word Template

Process Capability Analysis | Cp & Cpk Calculation Excel Sheet with Example

Run Chart Example | Concept & Interpretation of Result with Case Study | Industrial Example:

Risk Register | Download Risk Register Template:

Control Chart Excel Template | How to Plot Control Chart in Excel | Download Template

MTBF and MTTR Template, Format, Calculation | Manufacturing Example

OEE Means | Full Form | Download OEE Template

8D Report | Free Download of 8D Template or Format

Pareto Chart Excel Template | Download format

Fishbone Diagram Template With Example

How to calculate z-score in excel with manufacturing example

Corrective and Preventive Action Format, capa format, capa format in word, capa format in excel

Corrective and Preventive Action Format | CAPA with Example

Implementation of KAIZEN in Industry

5 Whys Excel Template , Download why why analysis excel format

Six Sigma Project Examples | 15+ Project Examples

07/04/202609/04/2024 by TECHIEQUALITY

Six Sigma Project Examples | 15+ Project Examples

Hello readers! Today we will be discussing on different types of Six Sigma Project Examples in manufacturing industries. As we know that Six sigma projects are different types like yellow belt, green belt, black belt and master black belt projects. We have already published a post on different types of six sigma belts. Different types of methodologies used in six sigma projects like DMAIC or DMADV, etc. similarly six sigma projects also classified into several types like lean six sigma project, six sigma projects, design of six sigma project.

Download the Six Sigma DMAIC Tools.

How to Identify the Six Sigma Projects?

Here, sharing my own experience that how was I identifying the Six Sigma project in my work zone. I was simply following the below steps to identify the Six Sigma project.

Identify the current problems or issues, like defects issues, high process or product characteristics variation, high rejection, high warranty issues, customer complaints, high breakdowns, reduction of energy consumption, cycle time reduction, lead time reduction, etc.
Categories the problems like A types, B types, C types and K types.

Problem types	Description
A type	Quality circle project problem
B type	SGA project problems
C type	Six Sigma project problem.
K type	Kaizen problems

After categorization of problems you can select the C type problem for six sigma projects. Once you finalize the number of projects as per prioritize my six-sigma committee and top management, you can prepare the six-sigma project charter.

Prepare the project charter.
Follow the six-sigma methodology like DMAIC.
Define phase, Measure phase, analyze phase, improve phase and control phase.

Six Sigma Project Examples:

Following are some example of six sigma project that you can consider to do but there are not limited to.

Reduction of COPQ.
Reduction of rejection, Defects, etc.
Process variation reduction.
Warranty reduction.
Cycle time reduction.
Lead time reduction.
Supplier rejection reduction.
Waste reduction and production optimization.
Breakdown time, MTTR and MTTBF improvement project.
Energy consumption reduction.
Conversion cost reduction.
Cost reduction project.
Six sigma projects on customer complaint.
Yield Improvement Project.
Scrap Reduction Project
Rework reduction project.
Process and Product failure improvement project.

How to write six sigma project charter?

The Six sigma project charter is the main part of the any type of 6-sigma project. Which is consist with some basic information about project, problem statement, scope, goal, tangible and intangible benefits, team members, and final the approval part. After getting the approval from concern personnel, you can start your project.

Let’s consider an example here for preparing the six-sigma project charter, for doing so we are going to consider here an example of the manufacturing industry for better understanding, suppose the manufacturing unit is producing automobile parts and somehow rejection% at process P-1 is high. At process P-1, they are manufacturing Part-1. For reducing the high rejection percentage at process P-1, the six- sigma certified holder has taken a project on it and prepared the project charter.

Follow the below steps to prepare the six-sigma project charter:

Form a Six sigma team including designation, and roles & responsibility of all members.
Minimum, Keep the past 3 to 6 months data for calculation of sigma level, DPMO, and defects contribution. for better result and considering with all environmental impact you can consider 12 months to 18 months data. More data will provide you best result. You can manually calculate the DPMO or you can use the DPMO Calculator as well. After calculating the DPMO value, then easily from six sigma conversion table you can find the sigma level. For the knowing the defects contribution you can use the Pareto chart.
Next part is the Problem statement, here you can write the statement by using the 5W1H or 5W2H template.
Define the scope, project goal, estimated benefits and project objectives.

First of all, try to form a six sigma team and define their project roles & responsibility, once you done the same next write the problem statement, same we are going to write here considering with the above example. We have used the 5W2H template to describe the problem statement.

As you know, there is high process rejection of Part-1 at process P-1.

Problem Statement:

What: high rejection of Part-1

Where: In Process P-1

When: during manufacturing of parts in three shifts

Who: Machine operators/ workforces.

Why: reason unknown

How often: monthly / daily

How much: you can mention here rejection in percentage or in PPM or in DPMO.

Project Goal:

Mainly describe the project objectives & goal like [1] to reduce the rejection% from x% to y%. or [2] To reduce the rejection PPP by 90% from x to y. [3] improve the sigma level e.g. 4 to 5.5.

Scope of project:

Here, you just mention the project boundary like what is included and what is excluded. For example, Process P-1 is included and process p-2 is excluded.

Estimated Benefits:

Tangible Benefits: Improvement of sigma level e.g. 4.4 to 5.5, Reduction of rejection e.g. 1.1% to 0.02%, DPPM from 11300 to 150, DPMO from 1800 to 25, and for example estimated cost saving 50 lakhs/annum.
Intangible benefits: For example, Increase Customer Satisfaction, Knowledge about 6-Sigma tools, Improved Presentation skill, improved analytical Knowledge, Improved team work & self, Problem Solving Skill developed.

Project Plan:

In the project plan section, you should take the target date of all 5 phases and monitor the actual date and delay of project. So that you can manage your total project period.

For example;

5-Phases	Target Date	Actual date
Define Phase
Measure Phase
Analyze Phase
Improve Phase
Control Phase

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Six Sigma Project Charter Template

07/04/202609/04/2024 by TECHIEQUALITY

Six Sigma Project Charter Template

Hello readers! Today we will discuss on a specific topic, which is related to the Six Sigma project charter. How effectively you can prepare the Six Sigma project charter so that each and everything will be in a single template for making the decision on the project for approval and next further project work. There are several methodologies and tools used in Six Sigma projects, but the popular methodologies are DMAIC and DMADV and similarly, so many tools are used in the project as well. We have already published the main important topic covering DMAIC Tools and some six sigma project examples in manufacturing industries. I hope both topics will be very helpful before preparing the Project charter. So, let’s read these topics first and then prepare the project charter. Without wasting your time you can download the Six Sigma Project Charter Template from the below-given link.

Download the Six Sigma Project Charter Template sample copy.

Before preparing the Six Sigma project charter you have to understand the methodology, project types, and 6-sigma belts, which will help you to make your project successful. The popular 6-sigma bets are yellow, green, black, and master black belts, and similarly, the Six-sigma project, lean Six-sigma, and design of Six-sigma project generally followed the different and different types of methodology like, DMAIC (Define, Measure, Analyze, Improve & Control), DMADV (Define, Measure, Analyze, Design and Validate).

Once you list out the problem set, you can start preparing the Six Sigma project charter to represent the project details and for getting approval. First of all, keep the past data of a minimum of 3 months, or for better results, you can consider 18 months of past data for representing the problem statement, problem/defects contribution, DPMO /DPPM calculation, and also for sigma level calculation.

Step by Step guide of Project Charter preparation with Manufacturing Example:

Let’s consider a company manufacturing a part PT-1 at process PRS-1. The rejection quantity of that part PT-1 is 2347 and the production quantity is 76000. The number of opportunities per unit is 5.

First of all, we are going to calculate the DPMO.

DPMO = Total Rejection quantities x 1000000/ (Total units x opportunities per unit)

= 2347 x 1000000/ (76000 x5)

= 6176

Now, I am going to prepare the Six Sigma project charter.

Project title: Reduction of rejection DPMO from 2347 to 25 (target is 98.9% reduction)

Problem Statement:

What: High rejection of part PT-1 of DPMO 2347

Where: At process PRS-1

When: During manufacturing of part PT-1.

Who: Machine workforce.

Why: Reason unknown

How often: Monthly

How much: DPMO 2347 per month.

Project goal: 98% reduction of monthly DPMO

Scope: Included Process PRS-1

Tangible Benefits: 60 lakhs/ Annum cost saving.

What are the key elements of a charter?

As you can see in the above project charter sample template, we have already highlighted the key elements of the Six Sigma project charter in yellow colour and these are the list below as;

Problem statement.
Project goals
Scope of the project
Estimated benefits/business case
Project plan. Etc.

What is the purpose of the project charter?

The main purpose of the project charter is to write down the key elements of the project and to get approval from the approver. And from time to time you have to update the Project plan status as well. It’s a synopsis of your Six Sigma project.

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DPMO Calculation, Formula, Template & Manufacturing Example

07/04/202609/04/2024 by TECHIEQUALITY

DPMO Calculation, Formula, Manufacturing Example & DPMO Excel Template

Hello readers! Today we will be discussing on DPMO calculation with manufacturing examples. The full form of DPMO is defects per million opportunities. Similarly, dpmo there are 3 more popular terms used in quality for the calculation of defect level and these are [1] DPPM, [2] DPO, [3] DPU. These terms are also frequently used in six sigma project work. If you would like to download the sample template of all 4 calculations in a single sheet then download it from below given link.

DPMO Calculation Excel Template–DOWNLOAD

Formula of DPMO, DPPM, DPO, DPU:

DPU (Defects per unit):

DPU Formula = Total number of Defects / Total units

DPO (Defects Per Opportunity):

DPO Formula = Total number of defects/ (number of units x defects opportunity per unit)

DPMO (Defects per million opportunities):

DPMO Formula = {Total number of defects/ (number of units x defects opportunity per unit)} x 1000000

DPPM (Defective Parts Per Million):

DPPM Formula = (Total Defective parts / Total parts) x 1000000

First of all, below example-1 is one of the scenarios that are given for calculating the DPMO, DPPM, DPO, and DPU for all my article readers. So, this is the task for you my readers for your better understanding. Similarly, we are also going to solve one of the scenario-based questions for calculating the DPMO, DPPM, DPU, and DPO.

Example-1 (Task for the reader):

Suppose a sheet metal automobile manufacturing company, produces an automobile part. In the press shop, we found that 4 parts had been rejected at press machine-1 & 9 parts at press machine-2. When a QA engineer had analyzed, he found that the total defective product has 16 defects. And defects opportunity per parts is 5 and total 1100 parts had been produced. Calculate the DPMO, DPPM, DPU and DPO?

Have you completed the calculation of above example-1 or not? If not yet then, we are going to help to calculate the same. First of all, note down the data, i.e. Total defects, Total defective parts, defects opportunity per part, total parts produced and total defects opportunity. I know that it will take more time for manual calculation of all calculations, that is why we are recommending you to download our excel automatic calculation template for easy and time-saving calculation. Downloading link is given at top of the articles just try to download the format or template. I would request you all my readers, you just calculate the DPMO and DPPM manually and try to match your value with Excel calculation, which is given below;

I hope you have completed the matching of the value calculated by the automatic excel template and your manual calculation. Now we will be discussing the different types of examples and will calculate the value by both manually and by using an automatic excel format. So, let’s get started.

Example-2:

Lets a company manufacturing a toy product and below are the data given in several processes. so, calculate the DPMO, DPPM, DPO and DPU of individual processes and overall process by manually and by using the excel template. And also try to compare both solutions.

Process-1 Data Table:

Total Defects	30 nos
Total Defective parts	20 nos
Defects opportunity per part	3
Total parts produced	840 nos

Process-2 Data Table:

Total Defects	102 nos
Total Defective parts	80 nos
Defects opportunity per part	4
Total parts produced	987 nos

Process-3 Data Table:

Total Defects	17 nos
Total Defective parts	16 nos
Defects opportunity per part	3
Total parts produced	1003 nos

Calculate the DPMO, DPPM, DPO and DPU of individual processes and overall processes by manually and by using the excel template?

Solution of Process-1:

DPU Formula = Total number of Defects / Total units

= 30/840

=0.0357

DPO (Defects Per Opportunity):

DPO Formula = Total number of defects/ (number of units x defects opportunity per unit)

= 30/(840×3)

= 0.0119

DPMO (Defects per million opportunities):

DPMO Formula = {Total number of defects/ (number of units x defects opportunity per unit)} x 1000000

= [30/(840×3)]x1000000

=11904.7

DPPM (Defective Parts Per Million):

DPPM Formula = (Total Defective parts / Total parts) x 1000000

= (20/840) x1000000

=23809.5

Similarly, Excel template calculation is given below as;

Solution of Process-2:

DPU (Defects per unit):

DPU Formula = Total number of Defects / Total units

= 102/987

= 0.1033

DPO (Defects Per Opportunity):

DPO Formula = Total number of defects/ (number of units x defects opportunity per unit)

= 102/(987×4)

= 0.0258

DPMO (Defects per million opportunities):

DPMO Formula = {Total number of defects/ (number of units x defects opportunity per unit)} x 1000000

= [102/(987×4)]x1000000

= 25835.86

DPPM (Defective Parts Per Million):

DPPM Formula = (Total Defective parts / Total parts) x 1000000

= (80/987) x1000000

= 81053.69

You can compare the answer with the below given Excel calculated value.

Solution of Process-3:

DPU (Defects per unit):

DPU Formula = Total number of Defects / Total units

= 17/1003

= 0.0169

DPO (Defects Per Opportunity):

DPO Formula = Total number of defects/ (number of units x defects opportunity per unit)

= 17/1003×3

=0.0056

DPMO (Defects per million opportunities):

DPMO Formula = {Total number of defects/ (number of units x defects opportunity per unit)} x 1000000

= [17/1003×3]x1000000

= 5649.7

DPPM (Defective Parts Per Million):

DPPM Formula = (Total Defective parts / Total parts) x 1000000

= [16/1003]x1000000

= 15952.14

Below are the excel calculation of the above value, you can match the value;

Overall Process DPMO Calculation:

For doing so we need a combined data table, so we have clubbed all the data of process-1,2 & 3 and given in below; the same part is produced in all 3 processes.

Total Defects	149 nos
Total Defective parts	116 nos
Defects opportunity per part	8
Total parts produced	2830 nos

DPU (Defects per unit):

DPU Formula = Total number of Defects / Total units

= 149/2830

= 0.0526

DPO (Defects Per Opportunity):

DPO Formula = Total number of defects/ (number of units x defects opportunity per unit)

= 149/2830×8

=0.00658

DPMO (Defects per million opportunities):

DPMO Formula = {Total number of defects/ (number of units x defects opportunity per unit)} x 1000000

= [149/8×2830]x1000000

= 6581.27

DPPM (Defective Parts Per Million):

DPPM Formula = (Total Defective parts / Total parts) x 1000000

= (116/2830) x1000000

= 40989.39

[Excel Calculation of DPMO]

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Process Flow Diagram Template | Examples |Symbols |PFD

07/04/202603/04/2024 by TECHIEQUALITY

Process Flow Diagram Template | Examples |Symbols |PFD

Hi Readers! Here, today we will be discussing the process flow diagram, its symbols, and practical examples. We have prepared a PFD template for sample and example basis, if you would like to download the free template or format of the PFD-process flow diagram then, go through the below-given link.

The process flow diagram template or format in excel-DOWNLOAD-PFD in Excel template or format.

What is a Process Flow Diagram- PFD?

The PFD or process flow diagram is a flow chart or process flow diagram or process mapping of a process. The PFD represents the process sequence and details (like a machine, activities, process sequence, relevant document, process control, decision, etc).

Symbols of Process flow diagram – PFD:

PFD/PFC has many symbols but we will discuss only common symbols. Details are given below;

Symbol Name	Function
Flowline	To show the process direction
Terminal symbol	It indicates the beginning or end of the Process flowchart
Process	Represent Process steps
Decision Symbol	Which shows the decision step of a process
Input / Output	Inputting or outputting data
Predefined process	Which indicates the predefined process
On-page connector	Pairs of on-page connectors are used to replace long lines on a flowchart page
Off-page connector	It is used when the target is on another page.
Delay	Which represents the delay period that is part of a process
Document	Document requirement
Multi-document	Multi-document requirement
Display	Machine display
Manual input	Data or information in the system
Manual Operation	It indicates the manual process

Process Flow Chart symbols / PFD

4 Steps to create a PFD-Process flow Diagram:

Step-1:

CFT team formation including the process owner.

Step-2:

List out the process, activities, decision, machine, control mechanism, etc

Step-3:

Sequentially write down the process, activities, and decisions of the process

Step-4:

Plot the diagram by using the PFD symbols.

Process Flow Diagram Example:

We have created two process flow diagrams, i.e. [1] without repetition of the process after the decision and [2] with repetition of the process after the decision. Both two types of PDF are given below;

Industrial Example:

Here we have taken the process flow diagram example of Training, which is one of the most powerful things to competent the workforce and enhance the skill of employees. So that optimum knowledge can be utilized for effective output from operation by employees at an organization. Hence if you would like to create a process flow chart of education and training operations then the below example will be helpful to prepare the same. This is only for reference and learning purposes.

We have prepared the PFD followed by the above steps:

Step-1:

We have formed a team including the HRD member.

Step-2:

Identified the activities below

Training needs identification
Prepare the training plan and schedule
Conduct the training as per schedule
Training feedback and effectiveness monitoring
Skill evaluation.

Step-3:

We have arranged the activities sequentially as given below of education and training operations.

Activities-1	Training needs identification
Activities-2	Prepare the training plan and schedule
Activities-3	Conduct the training as per schedule
Activities-4	Training feedback and effectiveness monitoring
Activities-5	Skill evaluation

Step-4:

We have prepared the PFD – process flow chart for education and training operations and details are given below;

FAQ:

What is the process flow?

The process flow is the flow chart that represents the process sequences or process mapping including machine details, control data, document reference, etc.

What is the difference between SIPOC and PFD?

The SIPOC diagram consists of 5 elements i.e. Supplier, Input, Process, Output, and Customer. the PDF is the process mapping that represents the process sequences.

What is flowchart?

The FC is a flow diagram or mapping of activities.

What are the 3 types of PFD?

[1] System PFD, [2] General PFD, [3] Detailed PFD

Free Templates / Formats of QM: we have published some free templates or formats related to Quality Management with manufacturing / industrial practical examples for better understanding and learning. if you have not yet read these free template articles/posts then, you could visit our “Template/Format” section. Thanks for reading…keep visiting techiequality.com

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C Chart Excel Template | Formula | Example | Calculation

07/04/202601/04/2024 by TECHIEQUALITY

C Chart Excel Template| Formula |Example |Calculation:

Hi Readers! Today, we will be discussing here on attribute type SPC chart i.e. C chart. Its formula, calculation, and industrial example. The C chart is also called the number of nonconformities chart. Where the sample size is constant. Read the below description to learn about its selection and application in industries. If you are interested in downloading the sample C Chart Excel Template then, click on the given below link.

Sample C Chart Excel Template with industrial example-Download.

Number of nonconformities chart (C Chart):

The C chart, attribute type SPC control chart, or the number of nonconformities chart is generally used to identify the common or special causes present in the process and is also used for monitoring and detecting process variation over time. It helps to determine whether the process is in a state of statistical stable or not. Overall, it indicates that special causes are present in the process or not, whether the process is under control or not, and process variability. This C chart is selected when there is a constant sample size and multiple defects per unit are present.

Selection of Attribute type SPC Control chart (C Chart):

Step-1: Data Types?

Condition: – Discrete type data (Attribute type data)

Step-2: Is the interest in nonconformities or multiple defects per unit?

Condition: – yes, multiple defects per unit

Step-3.:- Is the sample size constant?

Condition: – Yes, then use the C chart.

Description	Condition
Data Type:	Discrete type data (Attribute type data)
Is the interest in nonconformities or multiple defects per unit?	Yes, Multiple defects per unit present
Is the sample size constant?	Yes
Chart type:	C Chart

C Chart Formula:

The three important things need to be calculated before plotting the C chart i.e. [1] Centerline, [2] Upper control limit, & [3] lower control limit.

Centerline (CL) or C bar = Total number of nonconformities or defects / Number of samples

Upper control limit (UCL) = C-bar + 3 x Square root of C-bar

Lower control limit (LCL) = C-bar – 3 x Square root of C-bar

	The formula of C chart
CL or C- bar =	Total number of nonconformities or defects / Number of samples
UCL =	C-bar + 3 x Square root of C-bar
LCL =	C-bar – 3 x Square root of C-bar

How to plot a c chart in excel?

Here, I’m going to share my own industrial experience regarding the application and usage of a c chart in the manufacturing industry by providing a sample example for your quick learning and implementation in your organization. I have considered 50 sample sizes, and three different defects and collected the data for 30 days. Details of data are given below table.

Date	Constant sample size (n)	Defect-1	Defect-2	Defect-3	Total Defects
1	50	1	1		2
2	50	1	1	2	4
3	50	2	2	1	5
4	50	1	1		2
5	50	1	1	2	4
6	50	1	1		2
7	50	1	1	1	3
8	50	2	2	2	6
9	50	2	2	3	7
10	50	1	1	2	4
11	50	1	1	3	5
12	50	1	1	1	3
13	50	5	5	7	17
14	50	1	1		2
15	50	1	1	1	3
16	50	2	2	1	5
17	50	1	1		2
18	50	1	1	1	3
19	50	1	1	3	5
20	50	1	1		2
21	50	2	2		4
22	50	1	1		2
23	50	2	2	2	6
24	50	1	1	3	5
25	50	1	1	1	3
26	50	2	2		4
27	50	1	1	1	3
28	50	1	1		2
29	50	1	1	1	3
30	50	1	1	1	3

All the above three defects are attribute type defects. Before plotting the c chart in excel we have to calculate the three important things first, one is CL, UCL & LCL.

Calculation:

Centerline (CL) or C-bar:

Formula = Total number of nonconformities or defects / Number of samples

CL = 121 / 30 =4.033

UCL (Upper control limit):

Formula = C-bar + 3 x Square root of C-bar

UCL = 4.033 + 3* Square root of 4.033

UCL = 4.033+3*2.008

UCL = 10.0577

UCL = 10.058

LCL (Lower control limit):

LCL = C-bar – 3 x Square root of C-bar

LCL = 4.033 – 3* Square root of 4.033

LCL = 4.033-3*2.008

LCL = 4.033-6.024

LCL = -1.991 (the value is negative so LCL is Zero)

LCL = 0.00

	Calculation value
CL =	4.033
UCL =	10.058
LCL =	0

Follow the below step to plot the c chart in excel:

Step-1: open the excel sheet.

Step-2: Do the data entry on the Excel sheet.

Step-3: Select the data and then go to the insert option in the main menu and next to select line chart. The detail is mentioned in the below image.

C Chart:

With the help of the above data, we have plotted the c chart, which is given below. if you would like to download the C Chart Excel Template then, click here.

Interpretation of the above C Chart:

In the above C chart, we have seen that one defect value is beyond the upper control limit. It means on day-13 special cause was present in the process, so we have to take the action on it to control the process.

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SIPOC Template | SIPOC Diagram Example of Manufacturing & Service Industry

07/04/202601/04/2024 by TECHIEQUALITY

SIPOC Template | SIPOC Diagram Example of Manufacturing & Service Industry

Hi Readers! Today here, we will be discussing on SIPOC template and examples of sipoc diagrams of manufacturing and service industries. As you know that SIPOC is one of the most useful diagrams which is generally used for a better understanding of the process. In both the manufacturing and service industries are commonly used the two types of process mapping diagrams are. I.e. [1] PFD- Process flow diagram and another [2] SIPOC diagram. If you would like to download the free SIPOC excel template then, click on the given below download link.

Download the SIPOC template in excel format-SIPOC Excel format-DOWNLOAD Link

What is SIPOC Diagram?

The SIPOC diagram consists of 5 elements i.e. [1] Suppliers, [2] Inputs, [3] Processes, [4] Outputs, [5] Customers. The diagram is generally used for process mapping. It helps to understand the overview of the process in detail.

5 Steps to create a SIPOC Diagram:

Step-1:

Create a CFT team including the process owner of a particular process, which you are trying to draw.

Step-2:

Define the process, for example, let’s consider a process namely called Process-A and you are trying to draw an SIPOC diagram, so first of all you are supposed to list out the details activities of process-A in sequence with the help of the CFT team.

Step-3:

After listing out the details process sequence, find out the internal and external suppliers. Details are mentioned below example.

Step-4:

List out and identify the inputs, process, process output and then customers

Step-5:

Draw the Diagram by entering the above points in the appropriate places.

[SIPOC Template / Format]

SIPOC Diagram vs PFD – process flow diagram:

Both the SIPOC diagram and process flow diagram are used to represent the process mapping but the difference between the two is the elements that are used to represent the process details. In SIPOC, we use the 4 elements like supplier, input, process, output, and customer but in PFD, we use flow chart symbols, like the terminator, process, flow line (arrow connector), decision, document, connector, data, preparation, off-page connector, etc.

SIPOC Diagram Example of Manufacturing & Service Industry:

Manufacturing Industry Example:

Suppose a company manufactures automobile parts through foundry technology and they have planned to prepare a SIPOC diagram of one of the processes called green sand mould preparation.

Supplier	Input	Process	Output	Customer
Sand plant	Green sand	Filling green sand into drag pattern cavity	Drag mould	Mould making dept.
Sand plant	Green sand	Filling green sand into cope pattern cavity	Cope mould	Mould making dept.
Mould making dept.	Cope and drag mould	Core fitting	Mould with core fitted	Mould making dept.
Mould making dept	Mould with core fitted	Fitting of cope and drag mould	Final mould	Pouring dept.

Service Industry Example:

Let’s consider one of the service sectors of finance as an example bank, and we are going to draw a SIPOC diagram of an offline saving bank account opening process, which is given below;

Supplier	Input	Process	Output	Customer
…..	Application filled-up form	Offline checking and verification of documents deposited by the customer	Verified document	Document verification document
Document verification dept.	Verified document	Account creation	New saving bank account number	Account creation dept
Account creation dept	New saving account	Passbook issuing	New passbook	Mr. XYZ

FAQ:

What does sipoc stand for in Six Sigma?

Ans.: The SIPOC stands for Supplier, Input, Process, Output and Customer.

What is a SIPOC template?

The SIPOC template is a diagram which consists of suppliers, inputs, processes, outputs and customers. With the help of the SIPOC diagram, you can prepare the details process flow from start to end.

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Dispersion Analysis Cause & Effect Diagram Template |Download Excel Format

07/04/202605/03/2024 by TECHIEQUALITY

Dispersion Analysis & Process Classification Cause & Effect Diagram Template

Hi readers! Today we will discuss on types of Cause & Effect Diagram/Fishbone diagram. The cause and effect diagram is the most popular and frequently used tool among the seven QC tools. Basically Fishbone diagram is classified into mainly two types as [1] Dispersion Analysis Cause and Effect diagram, and [2] Process Classification Fishbone diagram. The Dispersion analysis fishbone diagram involves identifying the potential cause for a specific quality problem. However, a Process classification cause & effect diagram involves establishing causes related to the Process. In the manufacturing industry, both types of diagrams are used but Dispersion types are most frequently used to identify the potential causes of the quality-related problems. If you are interested in downloading the Dispersion Analysis Cause & Effect Diagram Template & Process Classification fishbone diagram, then click on the given below links.

DOWNLOAD– Dispersion analysis cause & effect diagram template. (4Ms).

Dispersion analysis Fishbone Diagram Excel Template. (4Ps)-DOWNLOAD.

DOWNLOAD– Dispersion analysis cause & effect diagram format. (8Ms).

Process Classification cause & effect diagram excel format-DOWNLOAD.

Steps for construction of Cause & Effect Diagram:

Form a CFT- Team with a multifunctional experienced workforce.
The facilitator will listen carefully to the member’s potential causes to represent it in a diagram.
Draw a backbone line from left to right, terminating at the Head, and write the Problem statement.
Draw the small bone and write the potential cause.

Advantages:

It helps to identify the potential cause to improve the process.
Helps in the root cause identification of the problem.
C&E diagram is easily constructed & understood.
It is an effective tool for the diagnosis of the various causes of the problem and helping to solve the problem.

Disadvantages:

Waste of time to identify the other causes that are not critical to the Problem.
It’s a time-consuming methodology.

Dispersion Analysis Cause & Effect diagram V/S Process Classification Fishbone diagram:

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Histogram Template with example | Download

07/04/202620/02/2024 by TECHIEQUALITY

Histogram Template with example | Download

The Histogram Template is prepared in a simple format with an industrial example. We have described the example in below, just go through this article and Download the Template / Format. It’s a very useful tool and is frequently used in manufacturing industries. The main function is to know the frequency distribution, symmetry, and skewness, and it also helps to determine the normality of data by drawing the bell curve.

DOWNLOAD [Histogram Template in Excel format].

Basic Information on Histogram:

A histogram is one of the 7QC tools and commonly used graph to show frequency distribution. Helps summarize data from a process that has been collected over a period of time.

A histogram is a representation of the frequency distribution of numerical data. it was first familiarized by Karl Pearson. A histogram is related to merely one type of variable data. You should calculate the interval value to represent the bins. Bins shall give an idea about the how much data falls within the selected data range’s width. Histogram gives the indication about data distribution as normal, skewed, or bi-modal.

How to use our Histogram Template:

Step-1: Download the Histogram Template from the above link.

Step-2: Carefully read the “Note” mentioned in the Excel template.

Step-3: Enter the reading only in the yellow color box. Then other values will calculate automatically and your histogram will be ready for interpretation.

Note:

1. Only yellow colour boxes are changeable

2. Make sure that the sum of frequency is equal to the total count, e.g. sum of frequency in a given example [example is given in histogram excel format, just download and see the example] is 30 and the count is also 30, if not then you have to adjust the parameters and frequency table in frequency distribution format for doing so click on the link given “How to adjust parameters and frequency table in Histogram Template?”.

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Thank you for reading…. Keep visiting Techiequality.Com

Let us know if you have any questions…and drop your comments below.

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Process Capability Analysis | Cp & Cpk Calculation Excel Sheet with Example

07/04/202610/02/2024 by TECHIEQUALITY

Process Capability Analysis | Cp & Cpk Calculation Excel Sheet with Example

Process Capability Analysis: – The Process Capability (Cp) and Process Capability Index (Cpk) are the important tools, which give an Idea about the Process Capability of a Stable Process. Here we will discuss on Calculation of Cp and Cpk with Examples. We are offering here Process Capability Excel Template / Format for you, hence click on the below links to Download the Excel Format.

DOWNLOAD (Cp & Cpk Excel Template / Format-Sample copy)

Process Capability (Cp):

Process Capability (Cp) is a statistical measurement of a process’s ability to produce parts within specified limits on a consistent basis
It gives us an idea about the width of the Bell curve.
The Process Capability for a stable process is typically defined as ((USL-LSL)/ (6 x Standard Deviation)).

Cpk-Process Capability Index :

It shows how closely a process is able to produce the output to its overall specifications.
More Value of Cpk means more process capable.
The Process Capability Index for a stable process is typically defined as the minimum of CPU or CPL.

Process Capability Analysis:

Industrial Example:

As per the Quality Assurance Plan, The shift engineers of Core Shop have started collecting the readings of the scratch hardness of Core. Given below are the details of Product Characteristics;

Specification of Scratch hardness is 70±10.

The Upper Specification Limit is 80.

The Lower Specification Limit is 60.

Tolerance is 20.

Scratch hardness readings Table:

Table-1

Sl.No.	1	2	3	4	5	6	7	8	9	10
SG 1	72.00	71.00	72.00	71.00	72.00	71.00	73.00	71.00	72.00	73.00
SG2	71.00	72.00	72.00	72.00	72.00	72.00	72.00	73.00	73.00	71.00
SG 3	72.00	72.00	71.00	71.00	71.00	73.00	72.00	72.00	71.00	73.00
SG4	70.00	70.00	70.00	70.00	71.00	70.00	71.00	70.00	71.00	70.00
SG 5	72.00	72.00	72.00	72.00	72.00	72.00	72.00	71.00	72.00	71.00

Table-1 [Scratch hardness readings Table]

Table-2

Sl.No.	11	12	13	14	15	16	17	18	19	20
SG1	71.00	72.00	71.00	71.00	72.00	73.00	71.00	72.00	73.00	71.00
SG2	72.00	73.00	73.00	72.00	71.00	72.00	71.00	73.00	71.00	70.00
SG3	72.00	71.00	73.00	72.00	72.00	72.00	71.00	71.00	71.00	70.00
SG4	71.00	70.00	71.00	70.00	70.00	71.00	70.00	71.00	71.00	70.00
SG5	70.00	70.00	71.00	71.00	72.00	71.00	72.00	71.00	71.00	72.00

Table-2 [Scratch hardness readings Table]

In the above two tables (Table-1 &2), we have taken the 100 readings i.e. (20 times X 5 readings at a time).

Range=Maximum Value-Minimum Value

Average of Range=2.15

Value of d2=2.326 (For Subgroup size 5)

USL = 80, LSL = 60.

Standard Deviation:

= Average of Range/d2

2.15/2.326

=0.92

Process Capability (Cp):

= ((USL-LSL)/ (6 x Standard Deviation))

(80-60)/ (6 x 0.92)

20/5.52

= 3.61

Process Capability Index (Cpk):

CPU:

= ((USL-Average of Mean)/3 x Standard Deviation)

(80-71.43)/ (3 x 0.92)

8.57/ 2.76

= 3.10

CPL:

= ((Average of Mean-LSL)/3 x Standard Deviation)

(71.43-60)/ 2.76

10.4211.43/2.76

=4.14

Cpk= 3.10 (minimum of CPU or CPL).

After doing the Process Capability Analysis on Scratch hardness readings, we got the below result value:

Characteristics: Scratch Hardness

Cp (Process Capability) = 3.61

Cpk (Process Capability Index) = 3.10

[ Cp & CpK ]

Process Capability Analysis with Manufacturing Example

The process engineer has collected the 100 nos laddle temperature reading and the same is mentioned in the below table.

Laddle Temperature Specification= 600 ± 15°C

USL = 615

LSL = 585

Table-1

	1	2	3	4	5	6	7	8	9	10
S1	605	599	610	605	603	604	600	609	605	601
S2	603	601	612	599	601	598	603	610	603	598
S3	604	598	609	610	612	609	605	612	604	603
S4	600	603	605	598	599	610	598	609	600	610
S5	602	602	607	609	605	612	599	605	609	603
Max.	605	603	612	610	612	612	605	612	609	610
Min.	600	598	605	598	599	598	598	605	600	598
Range	5	5	7	12	13	14	7	7	9	12
Average of Range	9.85
Mean	602.8	600.6	608.6	604.2	604	606.6	601	609	604.2	603
Average of Mean	603.92

Table-2

	11	12	13	14	15	16	17	18	19	20
S1	599	601	602	604	598	598	609	598	600	598
S2	610	598	602	603	603	603	605	603	603	610
S3	598	603	607	598	610	607	612	607	605	598
S4	609	610	609	603	603	598	604	598	607	602
S5	600	603	605	607	598	610	603	610	598	603
Max.	610	610	609	607	610	610	612	610	607	610
Min.	598	598	602	598	598	598	603	598	598	598
Range	12	12	7	9	12	12	9	12	9	12
Mean	603.2	603	605	603	602.4	603.2	606.6	603.2	602.6	602.2

d2=2.326

Standard Deviation = Average of Range / d2 = 4.23

Cp = (USL-LSL)/6*Standard Deviation = 1.2

CPU = ((USL-Average of Mean)/3 x Standard Deviation) = 0.872

CPL = ((Average of Mean-LSL)/3 x Standard Deviation) = 1.489

CpK = 0.872(minimum of CPU or CPL).

Note: Download the Cp & Cpk excel template or format and deploy it in manufacturing process. downloading links are provided at top of this Article.

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FAQ:

What is the difference between Cp & Cpk?

Ans.: Cp & CpK are termed as process capability and process capability index. In both cases, we would like to verify whether the process can meet the customer’s requirements or not. Generally, it is used when the process is under stable & statically control.

What is the formula of Cp & Cpk?

Cp= ((USL-LSL)/ (6 x Standard Deviation)) , where USL=Upper Specification Limit & LSL=Lower Specification Limit.

Cpk= Minimum of CPU or CPL, where CPU= ((USL-Average of Mean)/3 x Standard Deviation) & CPL= ((Average of Mean-LSL)/3 x Standard Deviation)

What are the good values of Cpk?

Generally, the customers provide the Cpk value to their supplier to maintain it in their manufacturing process. but for your knowledge, a Cpk value of 2 or greater than 2 is an excellent one.

What is cpk?

The cpk is the process capability index which shows how closely a process is able to produce the output to its overall specifications.

What is the IATF 16949 requirement of Statistical Concepts or SPC?

Application of statistical concepts in the IATF 16949 standard has been mentioned in Clause no-9.1.1.3, both Control chart (variable and Attribute) and process capability are the mandatory requirements. The application of statistical concepts shall be understood and used by the employees involved. We have published a separate article on Control Charts for our readers and you can Download Control Chart Excel Template / Format.

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