Tollgate Review DMA IC Premium Reduction & Delivery Improvement Champion –Sponsor –

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  • Tollgate Review DMA IC Premium Reduction & Delivery Improvement Champion Sponsor
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  • Tollgate Review DMA IC Project Title: Premium Reduction Contract
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  • Tollgate Review DMA IC Plant Premium 200x Detail Data was obtained from the Premium Web Site
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  • Tollgate Review DMA IC Plant Premium 200x Detail Data was obtained from the Premium Web Site
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  • Tollgate Review DMA IC Plant 200x Internal IPM Data was obtained from the Premium Web Site
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  • Tollgate Review DMA IC Plant 200x Internal IPM Data was obtained from the Premium Web Site
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  • Tollgate Review DMA IC SIPOC
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  • Tollgate Review DMA IC Plant Premium Reduction & Delivery Improvement Measure Date: 01 / 06 / 0x
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  • Tollgate Review DMA IC Cause & Effect Diagram
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  • Tollgate Review DMA IC Data Collection Plan
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  • Tollgate Review DMA IC Data Collection Plan
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  • Tollgate Review DMA IC Gage R & R Study u Repeatability Within Appraisers Appraiser# Inspected # Matched% Percent95.0% CT 2130 100(90.5, 100) 2302996.7(82.8, 99.9) # Inspected# Matched% Percent95.0% CT 302996.7(82.8, 99.9) u Appraiser agrees with him / herself trials u Reproducibility Between Appraisers u All appraisers assessments agree with each other
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  • Tollgate Review DMA IC Plant Premium Reduction & Delivery Improvement Analyze Date: 03 / 24 / xx
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  • Tollgate Review DMA IC Descriptive Statistics The median time for parts on backorder is 2.3 days. With a target of 2 days our process defect rate is 53% The median time for parts on backorder is 2.3 days. With a target of 2 days our process defect rate is 53%
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  • Tollgate Review DMA IC Descriptive Statistics Our process is stable with no clustering, mixtures, trends, and oscillations
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  • Tollgate Review DMA IC Identify variation Sources
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  • Tollgate Review DMA IC Identify variation Sources Data analysis shows that machine uptime and time to fill a backorder do not have a strong correlation not statistical root cause Data analysis shows that machine uptime and time to fill a backorder do not have a strong correlation not statistical root cause X1 - Uptime
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  • Tollgate Review DMA IC Identify variation Sources X2 Set Up / Change Over Data analysis shows that Set Up / Change Over Time and time to fill a backorder have no correlation not statistical root cause Data analysis shows that Set Up / Change Over Time and time to fill a backorder have no correlation not statistical root cause
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  • Tollgate Review DMA IC Identify variation Sources X3 Tool Availability No difference in either the center (median) or spread (variation) between tool Available yes vs. no not statistical root cause No difference in either the center (median) or spread (variation) between tool Available yes vs. no not statistical root cause
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  • Tollgate Review DMA IC Identify variation Sources X4 Press Availability The p values are greater than.05; we accept the null hypothesis ~ there is no difference in backorder time when a press is available yes vs. no The p values are greater than.05; we accept the null hypothesis ~ there is no difference in backorder time when a press is available yes vs. no
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  • Tollgate Review DMA IC Identify variation Sources X5 Spare Tooling Part Availability Although the medians appear different, there is not enough data to statistically conclude there is a difference there were only six samples when spare tooling was not available Although the medians appear different, there is not enough data to statistically conclude there is a difference there were only six samples when spare tooling was not available
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  • Tollgate Review DMA IC Identify variation Sources X6 Maintenance Response Time Statistical Root Cause with a p-value of.004 we reject the null hypothesis; there is a difference in times. When the maintenance call takes over 4 hours then the backorder time goes up significantly!! Statistical Root Cause with a p-value of.004 we reject the null hypothesis; there is a difference in times. When the maintenance call takes over 4 hours then the backorder time goes up significantly!!
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  • Tollgate Review DMA IC Identify variation Sources X7 Tool & Die Repair Time Statistical Root Cause with a p-value of.001 we reject the null hypothesis; there is a difference in times. When the maintenance call takes over 4 hours then the backorder time goes up Statistical Root Cause with a p-value of.001 we reject the null hypothesis; there is a difference in times. When the maintenance call takes over 4 hours then the backorder time goes up
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  • Tollgate Review DMA IC Identify variation Sources X8 Orders vs. Pulls No difference in either the center (median) or spread (variation) when we ask If the pull was greater than the order, yes vs. no not statistical root cause No difference in either the center (median) or spread (variation) when we ask If the pull was greater than the order, yes vs. no not statistical root cause
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  • Tollgate Review DMA IC Identify variation Sources X9 Low Volume No difference in either the center (median) or spread (variation) when we ask If the part is low volume, yes vs. no not statistical root cause No difference in either the center (median) or spread (variation) when we ask If the part is low volume, yes vs. no not statistical root cause
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  • Tollgate Review DMA IC Identify variation Sources X10 Red Tag or Care No difference in either the center (median) or spread (variation) when we ask If the material had any pieces in redtag, yes vs. no not statistical root cause No difference in either the center (median) or spread (variation) when we ask If the material had any pieces in redtag, yes vs. no not statistical root cause
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  • Tollgate Review DMA IC Identify variation Sources X11 Start/Stop Part No difference in either the center (median) or spread (variation) when we ask If this PN was a start/stop part, yes vs. no not statistical root cause No difference in either the center (median) or spread (variation) when we ask If this PN was a start/stop part, yes vs. no not statistical root cause
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  • Tollgate Review DMA IC Analyze Take - Aways - Maintenance Response Time is a significant contributor to Time to Fill Back Order (Y) - Tool & Die repair time is a significant contributor to Time to Fill Back Order (Y) - Both Maintenance Response Time and Tool & Die Repair Time impact Uptime but Uptime alone is not a significant factor - Other potential causes (Xs) did not show significant impact to Time to Fill Back Order - This statistical data indicates that in order to reduce the Time to fill a Back Order, which potentially leads to premium, we must reduce the Maintenance Response Time and the Tool & Die Repair Time
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  • Tollgate Review DMA IC Next Steps - Continue in the Improve Phase - Develop solutions to improve Maintenance Response Time and Tool & Die Repair Time - Collect Data from the Recommended improvement plan - Evaluate if corrective actions reduce or eliminate the impact of Maintenance Response Time and Tool & Die Repair Time on the Time to Fill a back Order / Premium
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  • Tollgate Review DMA IC Plant Premium Reduction & Delivery Improvement Improve / Control Date: 05 / 05 / xx
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  • Tollgate Review DMA IC Develop Solutions - Tool & Die Repair Time Solutions -Dedicated Tool & Die support on all Shifts -Use the Andon System to improve call priorities -Die Maker inspects and releases parts in place of a traditional release person -Document all Die changes in the log book -Dedicated tool makers for different die families - Maintenance Response Time Solutions -Dedicated Machine and Maintenance Repair support and on all shifts -Use the Andon System to improve call priorities -PC&L notifies maintenance when a part goes on back order -Maintenance Supervisor copied on all critical parts
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  • Tollgate Review DMA IC Test Solutions - Pilot The p values are less than.05; we reject the null hypothesis ~ there is a difference in backorder. The solutions have impacted both variation and median The p values are less than.05; we reject the null hypothesis ~ there is a difference in backorder. The solutions have impacted both variation and median
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  • Tollgate Review DMA IC New Capability Analysis Applying the goal of less than 2 days on backorder the solutions implemented improvement our process from 1.4 sigma to a 2 sigma process. Applying the goal of less than 2 days on backorder the solutions implemented improvement our process from 1.4 sigma to a 2 sigma process.
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  • Tollgate Review DMA IC Timeline for Full Solution Implementation - Department 11xx was the first module installed. - Implementation of the remaining modules that will utilize these solutions ar