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Six Sigma Project Place the team photograph here Organization Name
Plant Location Name of the Black Belt Team Members Date of Start Place the team photograph here
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Organization details Write briefly about your Organization and products/services
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DEFINE MEASURE & ANALYSE IMPROVE CONTROL D Define M & A Measure &
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Phase – 1- Problem Definition
Problem Statement Part number selected for study Other similar part numbers having the problem Process stages where the Problem is detected Current average rejection for last 6 months Maximum and Minimum rejection in last 6 months Maximum rejection in a month - Minimum rejection in a month -
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Phase – 1- Problem Definition
Number of lines/presses/machines used for processing Objective of the Project Annual Savings in Rs. Lakhs if the defect is made zero and horizontally deployed to other part numbers Response Variable / Attribute Specification (if the response is variable) Is R&R study required Yes / No If R&R study is required, % R&R to tolerance
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Phase – 1- Problem Definition
Process Mapping
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Phase – 1- Problem Definition
Project Planning Phase Month W1 W2 W3 W4 Define Measure & Analyze Improve Control Phases Planned Start date Planned Completion date Actual start date Actual completion date Status Define Measure & Analyze Improve Control
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Phase – 1- Problem Definition
Photograph of defect part
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Pareto (Based on last 6 months to 1 year data)
Phase – 1- Problem Definition Pareto (Based on last 6 months to 1 year data) Ojrpwg] 32% of the rejection is due to Blow holes. Qty produced: nos. Qty scrap – 540 nos. Scrap % Blow hole scrap – 172nos. Blow hole scrap % Double click on the graph to update the graph for your project
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COPQ (Cost of Poor Quality) Calculation
Phase – 1- Problem Definition COPQ (Cost of Poor Quality) Calculation Number of pieces rejected last month (for the part number identified for study) Number of pieces scrapped last month Number of pieces reworked last month Scrap cost/piece Rework cost/piece Total scrap cost (Rs. Lakhs) for last month Total rework cost(Rs. Lakhs) for last month Total Rejection cost (Rs. Lakhs) for last month Extrapolated Total rejection cost (Rs. Lakhs) for one year Ojrpwg] Note: Rejection should include both rework and scrap
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Phase – 1- Problem Definition
Suspected Sources of Variation for the Problem statement (SSV’s) Transfer the above SSV’s to the next slide, write the tools you have used in the column and identify which tool has been used for which cause. Also write the name of the tool in the Legend
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Phase – 1- Problem Definition
SSV’s Tool#3 Tool#1 Tool#2 Tool#4 Tool#5 Tool#6 Tool#7 Tool#9 Tool#8 Legend: Tool#1 – , Tool#2 – , Tool#3 – , Tool#4 – , Tool#5 – ,Tool# , Tool#7 - Tool# , Tool #9 -
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DEFINE MEASURE & ANALYSE IMPROVE CONTROL D Define M & A Measure &
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Phase – 2- Measure and Analyze
Analysis # 1 Objective: Technique/Tool used: -
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Phase – 2- Measure and Analyze
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Phase – 2- Measure and Analyze
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Phase – 2- Measure and Analyze
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Phase – 2- Measure and Analyze
Analysis # 1 Objective: Conclusion(s): -
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Phase – 2- Measure and Analyze
Analysis # 2 Objective: Technique/Tool used: -
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Phase – 2- Measure and Analyze
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Phase – 2- Measure and Analyze
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Phase – 2- Measure and Analyze
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Phase – 2- Measure and Analyze
Analysis # 2 Objective: Conclusion(s): -
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Phase – 2- Measure and Analyze
Analysis # 3 Objective: Technique/Tool used: -
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Phase – 2- Measure and Analyze
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Phase – 2- Measure and Analyze
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Phase – 2- Measure and Analyze
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Phase – 2- Measure and Analyze
Analysis # 3 Objective: Conclusion(s): -
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Phase – 2- Measure and Analyze
Analysis # 4 Objective: Technique/Tool used: -
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Phase – 2- Measure and Analyze
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Phase – 2- Measure and Analyze
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Phase – 2- Measure and Analyze
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Phase – 2- Measure and Analyze
Analysis # 4 Objective: Conclusion(s): -
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Phase – 2- Measure and Analyze
Total Analysis summary Cause(s) identified for the problem: Root cause(s) identified for the problem: -
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Phase – 2 – Measure and Analyze
Funneling Summary Funneling : Cause(s) # 1 Tool # 1 Funneling #1 Cause(s) # 2 Funneling # 2 Tool # 2 Funneling # 3 Cause(s) # 3 Tool # 3 Funneling # 4 Cause(s) # 4 Tool # 4
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DEFINE MEASURE & ANALYSE IMPROVE CONTROL D Define M & A Measure &
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Validation of the Root cause(s)
Phase – 3 - Improve Validation of the Root cause(s) Tool used: Data: Conclusion:
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Validation data for Root cause(s)
Phase – 3 - Improve Validation data for Root cause(s)
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Analysis of Data for Validation
Phase – 3 - Improve Analysis of Data for Validation
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Phase – 3 – Improve – Actions Summary
No Root cause(s) Actions Planned Planned Completion date Resp Actual completion date Status
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Phase – 3 – Improve Photograph of actions
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Phase – 3 – Improve Photograph of actions
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Phase – 3 – Improve Photograph of actions
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DEFINE MEASURE & ANALYSE IMPROVE CONTROL D Define M & A Measure &
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Phase – 4 – Control Phase No Root cause Variation analysis done
Type of control method decided Status of implementation
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Phase – 4- Control Analysis # 1 Objective: Tool/technique used:
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Data collected for Control
Phase – 4- Control Data collected for Control
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Phase – 4 - Control Results Before After
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Phase – 4- Control Project Summary
Number of drill down’s (funneling) done to reach the root cause(s): Number of predominant root cause(s) identified: Time in months for completing the project: Tools/Techniques used:
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Tangible Benefits derived through the project
Phase – 4 - Control Tangible Benefits derived through the project Overall scrap reduced from ppm to ppm 2. Defect XXX scrap reduced from --- ppm to --- ppm Cycle time reduced from ---- seconds to seconds. Estimated cost benefits is Rs per year. Intangible benefits derived through the project
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Phase – 4 - Control Current control plan
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Phase – 4 - Control Proposed Control plan
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