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4 Per Million
BY T.M. Kubiak
Perusing Process
Performance Metrics
Selecting the right measures for managing processes
Often, I have students ask for clarifica-
Percentage defective.
(DPMO).
Process sigma.
it is important to answer:
What is a defect?
appears.
Example of fraction
defective / Figure 1
Distribution plot
Normal, mean = 0, standard deviation =1
0.3
Density
manufacturing,
chemical or
paperwork) when
the outcome of
0.4
0.2
0.00135
-3
52 QP www.qualityprogress.com
0.00135
0
X
outcome. Of
course, expected
outcome means
the conditions of
Its important
3
the process is
fied in advance.
0.1
0.0
ample, assembly,
to hold true to
these definitions.
Process FPY1
1
Process FPY2
2
Process FPY3
3
/ Figure 2
Process FPY4
4
RTY
Defective
Defective
Defective
Defective
the ratio,
analysis.
DPMO
The DPMO metric is a measure of capability for discrete (attribute) data found by:
(Total number of defects)(1,000,000)
Total number of opportunities
tive is 0.27%.
DPU
following:
As you read through each of the process performance metrics below, consider
even paperwork.
Continuing with the pencil example,
lets calculate the number of opportuni-
organization.
Percentage defective
Blurred printing:
Too long:
Rolled ends:
36
118
11
only one way (the pencil slips in the fixture), so there are 40,000 opportunities for
this defect to occur.
There are three independent places
where dimensions are checked, so there
are (3) (40,000) = 120,000 opportunities
for this dimensional defect.
Recently, ASQs Six Sigma Forum discussion board has hosted lively exchanges on
the confusion over DPU, PPM and DPMO vs. Sigma level. Read the topic thread at
www.asq.org/discussionBoards/thread.jspa?threadID=8655&tstart=0&forumID=37.
August 2009 QP 53
i=1
defectives.
PPM is also used to refer to contami-
165,000,000
= 687.5
240,000
process.
of product.
Similarly, the FPY represents the percentage of units that completes a subpro-
0.23
1,000,000 = 9.2
PPM =
25,000
RTY = FPYi
PPM
consideration.
x 100
RTY = FPYi =
RTY
i=1
as follows:
Percentage in
specification
68.2689
86.6386
95.4500
98.7581
99.7300
99.9535
99.9937
99.9993
99.99994
99.999996
99.9999998
54 QP www.qualityprogress.com
Percentage
defective
31.7311
13.3614
4.5500
1.2419
0.2700
0.0465
0.0063
0.0007
0.00006
0.000004
0.0000002
Sigma level
1.00
1.50
2.00
2.50
3.00
3.50
4.00
4.50
5.00
5.50
6.00
Percentage in
specification
30.2328
49.8650
69.1230
84.1313
93.3189
97.7250
99.3790
99.8650
99.9767
99.9968
99.9997
Percentage
defective
69.76721
50.13499
30.87702
15.86869
6.68106
2.27504
0.62097
0.13499
0.02326
0.00317
0.00034
PPM
697672
501350
308770
158687
66811
22750
6210
1350
233
31.7
3.4
graphically.
fraction defective of
0.0668106, a percentage
defective of 6.68106%
Table 1.
Mean
0
1.5
0.2
A quick review of
USL
0.3
Density
Process sigma
LSL
Fraction
defective
0.1
Fraction
defective
Process
shift
0.0
-4
-3
-2
-1
understanding the
not 2 PPB.
Sigma level =
0.8406 + 29.37 - (2.221) ln (ppm).
By the way, Ive had numerous students ask me what happens to the defective products shown in Figure 2 (p. 53).
as we determined previously.
sigma level.
Choices abound
know that:
August 2009 QP 55