Six Sigma Programme Green Belt Project( doc29)

1SixSigmaProgrammeGreenBeltProjectFinalReportStephenDaleTrainingwavestartdate15thFebruary2000SCRAPREDUCTIONELECTRICALDESIGNFAULTSSSDBPROJECTREF:2610ProjectRef:GB001/00StartDate:15.02.00PlannedCompletionDate:31.05.00CurrentDate:1.06.00Group:InvensysDivision:IndustrialDrivesBusinessUnit:BrookCromptonCompany:BrookCrompton(Guiseley)Submittedby:StephenDaleDate:1.06.00GreenBelt21.PROJECTDEFINITION...................................................41.1....................................................ProblemStatement41.2.....................................................ProblemObjective41.3..............................ProjectselectionandParetoAnalysis42.CONTROLMEASURESANDSECONDARYBENEFITS..................82.1...................................................Definingthemetrics82.2..........................................................PrimaryMetric82.3.......................................................SecondaryMetric92.4.....................................................ProcessCapability102.5...............................................Otherbusinessbenefits103.TEAMDEFINITIONANDSELECTION..................................113.1...............................................................Definition113.2................................................................Selection114.PROCESSMAPPINGANDCAUSE&EFFECTANALYSIS..............124.1........................................................ProcessMapping124.2...............................................Cause&EffectAnalysis165.CSM&FMEAANALYSIS................................................185.1......................................CharacteristicSelectionMatrix185.2..................................FailureModesandEffectsAnalysis216.CONTROLPHASE.......................................................256.1......................................................FMEAActionPlan2636.2.................................................Detailsofactionplan266.3....................................Savingsplanandsavingstodate2841.PROJECTDEFINITION1.1.ProblemStatementDuringtheperiodJan–Dec1999,$29,407Scrap/ReworkcostswereincurredasaresultofOfficerelatedproblems.Ofthis$20,799werecausedbyElectricalDesignfaults,ofwhichfaultcode61E(QualityImprovementNotes–ConnectionError)accountedfor$9,973.Thisis47.9%ofallELDfaultsand33.9%ofallOfficerelatederrors.1.2.ProblemObjectiveReduceScrap/Reworkcostsattributedtofaultcode61Eby50%by31stMay2000yieldingdirectsavingsof$5,000p.a.1.3.ProjectselectionandParetoAnalysisThisprojectwasselectedbecausetherewasperceivedtobeanincreasingamountoftimespentonreworkbytheWindingDepartmentduetoincorrectconnectionsbeingspecifiedonorders.HistoricaldatawascollectedoveraperiodfromJanuary1999toDecember1999intheformofQualityImprovementNotes.AnalysisofthedatawasdoneusingParetoChartsinordertodeterminethemainaspectsoftheproblemthatimpactmostonthebusinessinrelationtoscrapandrework.(Value)61.3.2.SecondLevelParetoAnalysis61E61M6063Others9973.315359.713999.941337.128736.7333.918.213.64.529.733.952.165.770.3100.00100002000030000020406080100FaultCountPercentCum%Percent$ValueOfficerelatedReject/Reworkbyfaultcode1999(Value)MachineVeserHand226552758162.047.850.3100.098.050.370006000500040003000200010000100806040200DefectCountPercentCum%Percent$Value61EFaultsbyWindingType(Jan1999-Mar2000)7ThelasttwoParetoChartsshowhowthe61Efaultshavebeensplitdownfurtherintothetypeofwindingmethodusedandthetypeofdiagramthathasbeenthesourceoferror.TheParetosshowquiteconclusivelythatwindingdiagramscausethemostconcernonbothhandandveserwindings.Thiswouldappeartocomplywiththefactthatmostofthespecialwindingsareproducedbyoneofthesewindingmethods.NotethattheperiodcoveredbythedataintheselasttwoParetoChartsisfromJanuary1999toMarch1999.ConnectionWinding336112482.997.1100.097.170006000500040003000200010000100806040200DefectCountPercentCum%Percent$Value61EFaultsbyDiagramType(Jan1999-Mar2000)82.CONTROLMEASURESANDSECONDARYBENEFITS2.1.DefiningthemetricsThemetricsoftheprojecthavebeensetuptoshowthevalueofallcostsattributedtoscrapandreworkduetoincorrectconnections.Bymonitoringtheeffectsofanyactionstaken,scrapandreworkwillberecordedmonthlybyvalueandalsobyquantityofstatorstestedintheWindingDepartment.2.2.PrimaryMetricThePrimaryMetricrelatesdirectlytotheproblemstatementinthatitshowsthecostofscrapandreworkdueto61Eincorrectconnectionerrors.DownisGood61EScrap/ReworkCosts($)05001000150020002500300035004000Jan-99Mar-99May-99Jul-99Sep-99Nov-99Ja