Defects Per Unit / Defects Per Million Opportnities

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From the course by University System of Georgia

Six Sigma and the Organization (Advanced)

190 оценки

University System of Georgia

Six Sigma and the Organization (Advanced)

190 оценки

Course 1 of 4 in the Specialization Six Sigma Green Belt

This course is for you if you are looking to dive deeper into Six Sigma or strengthen and expand your knowledge of the basic components of green belt level of Six Sigma and Lean. Six Sigma skills are widely sought by employers both nationally and internationally. These skills have been proven to help improve business processes and performance. This course will introduce you to the purpose of Six Sigma and its value to an organization. You will learn about the basic principles of Six Sigma and Lean. Your instructors will introduce you to, and have you apply, some of the tools and metrics that are critical components of Six Sigma. This course will provide you with the basic knowledge of the principles, roles, and responsibilities of Six Sigma and Lean. Every module will include readings, videos, and a quiz to help make sure you understand the material and concepts that are studied. You will also have the opportunity to participate in discussions and peer review exercises to give you the opportunity to apply the material to your daily life. Registration includes online access to course content, projects, and resources but does not include the companion text The Certified Six Sigma Green Belt Handbook (2nd edition). The companion text is NOT required to complete the assignments. However, the text is a recognized handbook used by professionals in the field. Also, it is a highly-recommended text for those wishing to move forward in Six Sigma and eventually gain certification from professional agencies such as American Society for Quality (ASQ).

From the lesson

Management and Planning Tools & Business Results for Projects

In this module, Dr. Bill Bailey will introduce you to management planning tools and business results for projects. This module also begins with a Yellow Belt Refresher Area, since some learners may have entered this course without having taken the previous yellow belt material. This refresher area does not serve as a "replacement" for taking the yellow belt material. It is only a "patch" for those who already have some knowledge of six sigma, but find the yellow belt specialization to be too introductory for their current situation. If you find yourself struggling with the green belt material in this course, it is highly recommended that you travel through the yellow belt specialization before attempting the green belt content.

Yellow Belt Refresher Areas Explained1:26

Cause and Effect Diagrams7:21

Checksheets4:46

Flow Charts and Process Mapping6:09

Defects Per Unit / Defects Per Million Opportnities5:55

Roll Throughput Yield4:20

Affinity Diagram0:59

Activity Network Diagram0:55

Multivoting0:49

Nominal Group Technique0:45

Force Field Analysis4:07

Prioritization Matrices7:08

Tree Diagrams1:14

Control Charts - pt14:02

Control Charts - pt24:00

Meet the Instructors

David Cook, PhD
Assistant Professor of Mechanical Engineering Technology
Department of Mechanical Engineering Technology
Bill Bailey, PhD
Assistant Professor of Industrial Engineering
Department of Systems and Industrial Engineering

These are two common Six Sigma measures,

defects per unit and defects per million opportunities.

DPU or defects per unit,

is simply a ratio of the number of defects to the number of units produced.

Or the total number of defects found in a sample divided by sample size.

To calculate, you simply divide the total number of defects by the number of units.

Let's say, for example, that you're processing mortgage applications.

This month, your organization processed 75 applications.

In these applications, 12 errors or defects were found.

We would divide the number of defects, 12, by the number of units, 75.

There're 0.16 or 16% defects per unit.

We multiply the decimal by 100 to find the percentage.

So when we multiply 0.16 by 100 we find that about 16% of

the mortgages had an error.

But, we need to remember that a single mortgage application

could have multiple errors.

Let's say we're making automobiles.

In this month, we've produced 1000 new cars.

Automobiles are complex machines and many things can go wrong.

We found 9000 defects in our automobiles.

When we divide the number of units produced,

1,000 into the number of defects, 9,000.

We find that we have 9 defects per unit.

Some units may have more defects and some may have none at all, but

the average number is 9.

Defects Per Million Opportunities, for this measure, we want to convert our

defects, or errors, to see how many there would be out of a million opportunities.

First, we should define opportunities.

Every possible defect in a product or

error in a service represents an opportunity.

So from our mortgage application example, let's say there are 30 different fields

that need to be properly filled out in the application.

We multiply the number of fields, or places where an error could occur,

by the number of mortgages processed.

30*75 = 2250 opportunities for

error in our 75 units.

To calculate DPMO we first divide the defects by the opportunities.

Then we multiply this number by 1 million.

In our example, there were 12 errors.

And we just calculated opportunities, and

found that the 30 fields on 75 applications

represented 2,250 opportunities for error.

Then we divided 12 by 2,250 and

we get 0.00533,

multiplying this number by 1 million,

gives us our defects per million opportunities of 5,333.

If you´ve already calculated DPU, or defects per unit,

you can use a little simpler formula.

You can divide DPU, defects per unit, by the number of opportunities per unit.

That and multiply that by 1,000,000.

As you can see, you'll get the same result.

This measure gives us a different perspective regarding errors and defects.

Let's turn to our automobile example again.

We found that we had an average of nine defects per vehicle or

9,000 defects across 1,000 vehicles.

Consider that automobiles are complex machines.

There're a lot of opportunities for error or defects.

Let's say there're 500 opportunities for a defect in each vehicle.

Actually, there're probably many more.

If we multiply the number of opportunities per vehicle by the number of vehicles,

we find that we have 500,000 opportunities for defects.

Remember, to get DPMO we first divide defects by opportunities.

We had 9,000 defects, so we divide 9,000 by 500,000.

This equals 0.018.

We then multiply this by one million.

Again we could use the shortcut but since we have already calculated DPU and

the result is the same.

Remember, defects per unit is simply the number of defects found in a sample

divided by the number of units in that sample.

To calculate defects per million opportunities,

we first have to calculate the number of opportunities.

We get this by multiplying the number of opportunities for

error in a single unit by the number of units in our sample.

This gives us the total number of opportunities.

Then, we divide the number of defects by total opportunities, and

multiply by one million.

Or, we can use the shortcut, and

divide DPU by the number of opportunities for error per unit.

And multiply that result by one million.

In either case, the result is our DPMO, or defective parts per million opportunities.

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