Calculating DPMO and Process Sigma Value

The Define phase stated that the ultimate aim of the process was to create a production drone with a flight time in operation of at least 2.500 hours (LSL) to minimize delays in order fulfillment cycle time. It was pointed out in the Define phase that there should be no more than one flight with delayed or incomplete orders due to flight time per 1000 flights. This has repeatedly been a problem plaguing the DCD group. This causes additional drones to be placed in service or for additional labor to work overtime, with the potential for additional expenses or loss. Looking at the Individuals control chart for the baseline performance (current Prototype 1), and noting that the upper control limit is only 2.466 hours, shows that currently no drones are meeting this specification of 2.500 hours. Note that it is acceptable to use specification limits to compare to control limits for data presented on Individual control charts. Therefore the yield is zero. The resulting defects per million opportunities (DPMO) are calculated, and the DPMO can then be converted into a process sigma value. Answer the following questions for these characteristics.

1. What is the CTQ?

2. What is the defect?

3. What is the unit?

4. What is the opportunity?

5. How many prototypes meet minimum specification?

6. What is the defect rate for the current design and its process sigma value?

What is the desired defect rate (calculate long-term DPMO and Cpk)?