六西格玛黑带项目案例

DefineSection1ClimateControlsOEMProductsGroupReduceReturnsof24245SIXSIGMABLACKBELTPROJECTCANDIDATE:PETERWRIGHTCHAMPION:KEVINKIDDERSTARTFEBUARY18,2002ESTIMATEDCOMPLETIONJULY15,2002DefineSection2ClimateControlsOEMProductsGroupDefineProjectDMAICREVIEWDEFINEMEASUREANALYZEIMPROVECONTROLDevelopcharterMaptheprocessUnderstandthevoiceofthecustomerMeasureSection3ClimateControlsOEMProductsGroupSIPOCSuppliers–Inputs–Process–Outputs-CustomersInputs24221RawCastingSuppliersProcessOutputsCustomers24245MachineMainValveSeatAcceptable24245MexicaliTexasDieCastingModernMetalChinaPrecisionReceiveInspectRawCastingInspectMainValveSeatDefineSection4ClimateControlsOEMProductsGroupProjectOverview:CustomerisfrustratedbyfailuresduetotheMainValveSeatdefects.•2%Rejects20,000assemblies-400rejectsdaily.Excessivereworktomainvalveseat.ExcessivereturnstotheLongBeach.DefineSection5ClimateControlsOEMProductsGroupExecutiveSummary:ReducetheMainValveReworks/ReturnsCreateaprocessthatis1.67CpkcapableDefineSection6ClimateControlsOEMProductsGroupGoal:Reducecurrent24245PPMReturnsto500PPMSavingstoMexicali$25,000annuallySavingstoLongBeach$40,000annuallyProjectedImprovement:ReducefailuresduringMexicaliAssemblyandtestCreatemorerobustmachiningandinspectionofthemainvalveseatDefineSection7ClimateControlsOEMProductsGroupSixSigma:TEAMCHARTERProductImpacted110BodyProductImpactedSales(’03proj$)BlackbeltXGreenbeltPeterWrightTelephoneNumber1-310-900-2395ChampionKevinKidderSBU&PlantWaterHeatingStartDateFeb.18,2002TargetCompletionDate30Sep2002ElementDescriptionTeamCharter1.Process/Product:Theproductionprocessinwhichopportunityexists.Kingsburymainvalvemachining.Machiningdefectsonmainvalveresultinginleakingofmainvalveseat.2.ProjectDescription:DescribetheProject’sPurposeandscope.ToreducetheDefectsonthemainvalveseatforPartNumber24245.3.Objective:WhatimprovementistargetedandwhatwillbetheimpactonRTY,COPQandC-P?BaselineActualGoalEntitle-mentunitsSeeattachedDefinitionsheetforexamplesQualityMetrics:RTY,DPU,DPPMQuality2%2%.2%.1%RTYCostofPoorQualityCOPQ$65k$65k$2.5k$1.25kdollars4.BusinessResults:(in2000Dollars)Whatistheimprovementinbusinessperformance(eg-salesandincome)anticipatedandwhen?ReductionoftherejectsatMexicaliwillresultinlessdisassemblyhigherRTY,thusareductionintheCOPQduetothisdefect.Estimatedpaybackforthetwoplantsis$62.5kperyear,effectiveFiscalyear2003.5.Teammembers:Whoarethefull-timemembersandanyexpertconsultants?KevinKidder–ChampionLeonelGarcia–CustomerRicardoPartida–QualityEngineer110Line6.ProjectScope:Whichpartoftheprocesswillbeinvestigated?MainValveSeat242457.BenefittoExternalCustomers:Whoarethefinalcustomers,whatbenefitwilltheyseeandwhataretheirmostcriticalrequirements?Rheem,AmericanWaterHeatingbenefitwillbelongerlifeandlessreturnsduetoleakingongasfromthemainvalveseat.8.Schedule:Givethekeymilestones/dates.ProjectStart2/15/2002FocusonprojectsM-Measurement“M”Completion3/15/2002thatcanbefinishedA-Analysis“A”Completion4/15/2002In4-6monthsmax.I-Improvement“I”Completion6/15/2002C-Control“C”Completion7/15/2002Note:ScheduleappropriateSafetyReviews.SafetyReviewsProjectCompletion8/15/20029.SupportRequired:Willyouneedanyspecialcapabilities,hardware,etc?Newmachineformachiningthemainvalveseat.Newopticalinspectionequipmentforinspectingthedimensionanddefectsinthemainvalveseatarea.ProjectCharter24245MainValveSeatDefineSection8ClimateControlsOEMProductsGroupMeasureProjectDMAICREVIEWDEFINEMEASUREANALYZEIMPROVECONTROLDataCollectionDataAnalysisProcessSigmaProcessAnalysisMeasureSection9ClimateControlsOEMProductsGroupDamagedMainValveSeatAcceptableMainValveSeatMeasureSection10ClimateControlsOEMProductsGroupStartPartsMachinedinLongBeachOK?Scrap/ReworkPartsKPIVsMeasurementKPOVsNPackage&ShipOK?ReturntoLongBeachNYAssembly&TestYSOPMicroscopeRTYScrap$$ProcessCpkSOPMacPacQuantityRightP/N?RightAddress?SOPMicroscopePPMRTY$$returnedSOPRTYAss’ydrawingWorkinstructionsSpecificationSOPCycletimeRejectrateScrap$$$DrawingWorkinstructionsWorkinstructionsAss’ydrawingWorkinstructionsAss’ydrawingWorkinstructionsOK?NReturntoLongBeachY1MeasureSection11ClimateControlsOEMProductsGroupPackageandShipKPIVsMeasurementKPOVsSOPMicroscopeRTYScrap$$ProcessCpkDrawingWorkinstructions1RTYScrap$$ProcessCpkCustomerSatisfactionOK?ReturntoMexicaliNYMeasureSection12ClimateControlsOEMProductsGroup22.9%Fugaexterna14.09%F.valvulaPpal.Baj7.98%F.GasPpal.Pos.Pi5.97%RangoCorto5.91%TV,TV2,TVO5.79%FugaxGC4.77%RangoLargo4.46%F.ValvulaPpal.Alt4.16%PilotoReg.3.55%FugaValv.Mag.PARETODEFECTSFORW0-W9FROM09/01/2001TO03/12/2002DEFECTCODESFugaexternaF.valvulaPpal.BajF.GasPpal.Pos.PiRangoCortoTV,TV2,TVOFugaxGCRangoLargoF.ValvulaPpal.AltPilotoReg.FugaValv.Mag.30%20%10%0%22.9%14.09%7.98%5.97%5.91%5.79%4.77%4.46%4.16%3.55%RTYF.ValvulaPpal.Baja=MainValveLeakExternalLeakMultiplepossibilitiesforthisdefectMainValveLeakSpecificMeasurableActionOrientedRealisticTime&ResultsConstraintsAnalyzeSection13ClimateControlsOEMProductsGroupDMAICREVIEWDEFINEMEASUREANALYZEIMPROVECONTROLIdentifyingCausesVerifyingCausesSelectingSolutionAnalyzeSection14Climat