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

Tollgate Review

D M A I C

Premium Reduction & Delivery Improvement

Champion –Sponsor –

Tollgate Review

D M A I C

Project Title: Premium Reduction

Contract

Department Customer (internal/external):Duration internal: PC&LSponsor:

CTQ addressed:Eric Crump PC&L Manager - Project Leader

Marne Cario PC&L General SupervisorBusiness Driver(s) Impacted:

Project Scope:

Tools UsedDefine

actual `Measure

actual

Analyzeactual

Improveactual

Controlactual Control and Response Plan

Total Months: 6August 2004 - February 2005

Contract / SIPOC / Graphs

Preliminary Problem Statement:

Aug

Rachel Heidenreich

PC&L

Premium / IPM (Internal & External)

Premium Cost Reduction / IPM Internal And External Delivery Improvement

Donnell Conner

Champion: Marybeth CunninghamTeam Members

Tool EngineerMFG Supervisor

Role

Dec

Jim AltierTom CathelineWilliam KatkoJohn Salerno

Nov

Quality Engineer Green Belt CandidateGreen Belt Re-Certif ication

Function

Manufacturing Support

Black Belt Candidate

Process Mapping, Cause and Effect Diagram, Data collection Plan, MSA

DPMO/Capability, Hypothesis Testing/Root Cause Analysis

Solution generate, Pilot on Department 1108, Moods Median Test, Test for Equal Variance

Mar Apr

Ken Dillon PC&L Scheduler - Project Leader

Jan Feb

Chris Kushmaul Master Black BeltMaster Black BeltShipping Supervisor

Sep Oct

In Scope - Reduction of all Premium from Pt 11

Green Belt CandidateGreen Belt Re-Certif icationProject Coach

Green Belt Candidate

Green Belt Candidate

Text: Plant has been experiencing high premium transportation over the past 2 years. 2003 premium was over $220,000 and 2004 premium is over $250,000 thru July. In addition to high premium, Plant 11 has experienced internal and external delivery issues to several customers. Delivery Performance has created several concerns from the DCS Business Line because of the impact to their final customers. The goal of this project is to reduce Premium by 40% and reduce IPM by 45%

Tollgate Review

D M A I C

$0

$20,000

$40,000

$60,000

$80,000

$100,000

$120,000

$140,000

$160,000

$180,000

$200,000

BehindSchedule

InternalQuality

SupplierQuality

Trans /Customs

DeliverMiss

Late Entry Mislabeled Cust. Req /Inv. Adj

Req /Inventory

Adj.

Part Cert.Delay

Plant Premium 200x Detail

Data was obtained from the Premium Web SiteData was obtained from the Premium Web Site

Tollgate Review

D M A I CPlant Premium 200x Detail

$220

,019

$20,

492

$7,3

38

$1,8

50

$1,6

12

$1,1

10

$659

$300

$0

$50,000

$100,000

$150,000

$200,000

$250,000

BehindSchedule

Trans /Customs

DataProcessing

Engineering InternalQuality

Deliver Miss Req /Inventory

Adj.

ToolCapacity


Tollgate Review

D M A I CPlant – 200x Internal IPM


27 0 023

9

2,04

7 2,50

7

2,16

9

4,89

4

7,65

5

261

3,83

4

2,89

2

9,25

2

0

1,000

2,000

3,000

4,000

5,000

6,000

7,000

8,000

9,000

10,000

Jan Feb March April May June July Aug Sept Oct Nov Dec YTD

Tollgate Review

D M A I CPlant 200x – Internal IPM


3,22

5

2,20

6

508

799

2,08

9

1,97

6

243

1,59

6

0

500

1,000

1,500

2,000

2,500

3,000

3,500

Jan Feb March April May June July YTD

Tollgate Review

D M A I CSIPOC

Process Name: Plant 11 Terminal Manufacturing ProcessProcess Owner: Plant 11 Premium Reduction Team

Suppliers Inputs Process Outputs(Providers of the required resources)

(Resources required by the process)

(Deliverables from the process)

Customer Forecast Requirements• Pulls• Orders Parts Shipped on Time INTERNAL

• MexicoPC&L Production Schedules • Mississippi

Quality PPAP Good Quality PartsTool ReleasePress ReleasePart Inspection (PPC)

Manufacturing Production Right Quantities

Tool Room Tools• Tool & Die Makers Set - UP

EXTERNALCorrectly Labeled • Lear

Tool Engineer Support • Yazaki• PS&G

Maintenance Support • CondumexChange-over

Terminal Store Matrial HandlingShippingDevelop Store Goal

Suppliers Raw Material

Customers(Stakeholders who place the requirements on

the outputs)

Customer Requirements

Forecast• Pulls (Internal)

• Orders (External)

• Scheduling• Manufacuturing

SHIPfrom OHIO

TERMINALS

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D M A I C

Plant Premium Reduction & Delivery Improvement

Measure

Date: 01 / 06 / 0x

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D M A I CCause & Effect Diagram

(Goal Changes)

(Note comment from Red Tags?)

(1 - Group with FTQ?) Should add up to84

(1 - Group w / Un-forcasted orders / pulls?)

PC&L Manufacturing Information Systems

Customer/Supplier Eng/Tool Room/Maint. Quality

Why do We have missed/late shipments?

(x) Lack - Order Fillers 1

(x) Critical Parts List

(x) Terminal Store Picks

(x) Partial Reels

(x) Lack - Raw Material

(x) Mtl Movement Delays

(x) Labor Allocation/Job

(x) Operator Training

(x) Care Insp. Coverage

(x) Line Insp. Coverage

(x) Absenteeism

(x) Uptime

(x) Lack - Real Time Info

(x) Shipping Patterns 1

3

2

(x) Scrap

(x) Press Availability 4

2

1

1

7

(x) Inventory Visibility

(x) Real Time Data

(x) Label

4

1

(x) Goal Changes

(x) Defective

Raw

(x) Pull Variations

(x) Increased Pulls

(x) Unforseen Orders/Pulls

5

2

6

Changeover Time 6

Issues Running 2 Precious Metal

Labor Resourcing/Job Ass

6Setup Times

3 Tool Availability

6 Tool Capability

Unplanned 3 Mtce. Downtime

Make vs Buy

Low Vol. & 4 Obsolete Parts

Spare Tooling Parts 4

Spare Equip. Parts

Mtce. Response Time 6

(x) PPAP

(x) Red Tags

(x) FTQ

3

1

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D M A I CData Collection Plan

Time Period (Y) (X1) (X2) (X3) (X4) (X5)

Joe Bonneau John Salerno Joe Bonneau Ken Dillion Ken Dillion John Salerno

Name of Factor: Operator (1) (2) Trial Part NumberTime to fill back

orderUptime Set up / Change

OverTool

AvailabilityPress Availability Spare Tooling Part

Availability

Operational Definition

The uptime of the press while the back order part number is

in the machine

Time to convert good part to good

part

Sitting on ready rack

Is an acceptable press available to

the run part?

The time it takes to get spare toolign

when parts are not available

Type of Data: Continuous Continuous Discrete Dicrete Continuous

Specific to:

P/N's

Measure

Data Collection Plan

Tollgate Review

D M A I C

Time Period (Y) (X6) (X7) (X8) (X9) (X10)Joe Bonneau Donnell Conner John Salerno Marne Cario Marne Cario Bill Katko

Name of Factor:Operator (1)

(2) Trial Part Number

Time to fill back order

Maintenance Response Time

Tool & Die Response Time

Unforeseen Orders / Pulls

Low Volume Red Tag

Operational Definition

Time from when a call is placed to the time the work is complete

The difference in time between when a tool

has failed & marked on the board & when the machine is running

Difference between the

forecast & the actual pull

Is this part number low

Volume?

Is this part red tag or care?

Type of Data: Continuous Continuous Continuous Discrete Discrete

Specific to:Rounded to the hour

checkedBuild area

1118First time? Quality?

P/N's

MeasureData Collection Plan

Data Collection Plan

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D M A I CGage R & R Study

Repeatability– Within Appraisers

Appraiser # Inspected # Matched % Percent 95.0% CT

21 30 30 100 (90.5 , 100)

2 30 29 96.7 (82.8 , 99.9)

# Inspected # Matched % Percent 95.0% CT

30 29 96.7 (82.8 , 99.9)

Appraiser agrees with him / herself trials

Reproducibility– Between Appraisers

All appraisers assessments agree with each other

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D M A I C


Analyze

Date: 03 / 24 / xx

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D M A I C

1 4 7 10 13

95% Confidence Interval for Mu

1.5 2.5 3.5

95% Confidence Interval for Median

Variable: (Y)

A-Squared:P-Value:

MeanStDevVarianceSkewnessKurtosisN

Minimum1st QuartileMedian3rd QuartileMaximum

2.6522

2.5589

1.6000

5.2690.000

3.186092.890368.354191.320741.59636

115

0.3000 1.0000 2.3000 5.4000

14.0000

3.7200

3.3212

2.7000

Anderson-Darling Normality Test

95% Confidence Interval for Mu

95% Confidence Interval for Sigma

95% Confidence Interval for Median

Time a Part is on Backorder (days)USL = 2 Days

DPMO = 1.4sigma process

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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D M A I CDescriptive Statistics

1106010

14

12

10

8

6

4

2

0

Observation

(Y)

0.5296

0.4704 3.000076.333376.0000

0.5370

0.463010.000058.495758.0000

Approx P-Value for Oscillation:

Approx P-Value for Trends:Longest run up or down:Expected number of runs:Number of runs up or down:

Approx P-Value for Mixtures:

Approx P-Value for Clustering:Longest run about median:Expected number of runs:Number of runs about median:

Run Chart for (Y)

Our process is stable with no clustering, mixtures, trends, and oscillationsOur process is stable with no clustering, mixtures, trends, and oscillations

Tollgate Review

D M A I CIdentify variation Sources

Factor Name Data Type Analysis Tools Statistically Significant

X1 Press Uptime ContinuousSimple Linear Regression Mood's Median Test Test for Equal Variances

No

X2 Set Up / Change Over ContinuousSimple Linear Regression Mood's Median Test Test for Equal Variances

No

X3 Tool Availability DiscreteMood's Median Test Test for Equal Variances

No

X4 Press Availability DiscreteMood's Median Test Test for Equal Variances

No

X5Spare Tooling Part Availability

DiscreteMood's Median Test Test for Equal Variances

No

X6Mantenance Response Time

ContinuousSimple Linear Regression Mood's Median Test Test for Equal Variances

Yes - Difference in Center

X7Tool & Die Response Time

ContinuousSimple Linear Regression Mood's Median Test Test for Equal Variances

Yes - Difference in Center and variation

X8 Orders vs. Pulls DiscreteMood's Median Test Test for Equal Variances

No

X9 Low Volume DiscreteMood's Median Test Test for Equal Variances

No

X10 Red Tag or Care DiscreteMood's Median Test Test for Equal Variances

No

X11 Start-Stop Part DiscreteMood's Median Test Test for Equal Variances

No

Tollgate Review


X1

Y1

9080706050403020100

30

25

20

15

10

5

0

S 3.69418R-Sq 3.7%R-Sq(adj) 2.9%

Fitted Line PlotY1 = 4.632 - 0.04227 X1

Data analysis shows that machine uptime and time to fill a backorder do not have a strong correlation – not statistical root causeData analysis shows that machine uptime and time to fill a backorder do not have a strong correlation – not statistical root cause

Regression Analysis: Y1 versus X1 (Uptime) The regression equation is Y1 = 4.632 - 0.04227 X1 S = 3.69418 R-Sq = 3.7% R-Sq(adj) = 2.9% Analysis of Variance Source DF SS MS F P Regression 1 62.52 62.5237 4.58 0.034 Error 120 1637.63 13.6470 Total 121 1700.16

Regression Analysis: Y1 versus X1 (Uptime) The regression equation is Y1 = 4.632 - 0.04227 X1 S = 3.69418 R-Sq = 3.7% R-Sq(adj) = 2.9% Analysis of Variance Source DF SS MS F P Regression 1 62.52 62.5237 4.58 0.034 Error 120 1637.63 13.6470 Total 121 1700.16

X1 - Uptime

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D M A I C

X2

Y1

14121086420

14

12

10

8

6

4

2

0

S 2.95590R-Sq 0.7%R-Sq(adj) 0.0%

Fitted Line PlotY1 = 3.108 + 0.08494 X2

Mood Median Test: Y speed versus x2 speed Mood median test for Y speed Chi-Square = 0.02 DF = 1 P = 0.899 Individual 95.0% CIs x2 speed N<= N> Median Q3-Q1 ----+---------+---------+---------+-- Long 10 9 2.30 5.60 (--------*------------------------) Short 49 47 2.30 3.90 (-----*-) ----+---------+---------+---------+-- 1.5 3.0 4.5 6.0 Overall median = 2.30

Mood Median Test: Y speed versus x2 speed Mood median test for Y speed Chi-Square = 0.02 DF = 1 P = 0.899 Individual 95.0% CIs x2 speed N<= N> Median Q3-Q1 ----+---------+---------+---------+-- Long 10 9 2.30 5.60 (--------*------------------------) Short 49 47 2.30 3.90 (-----*-) ----+---------+---------+---------+-- 1.5 3.0 4.5 6.0 Overall median = 2.30

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 causeData analysis shows that Set Up / Change Over Time and time to fill a backorder have no correlation – not statistical root cause

Mood Median Test: Y versus X2 Mood median test for Y Chi-Square = 0.09 DF = 1 P = 0.761 Individual 95.0% CIs X2 N<= N> Median Q3-Q1 --+---------+---------+---------+---- No 34 35 2.40 4.40 (-------------------*------------) Yes 24 22 2.15 4.10 (--------------*-----------------) --+---------+---------+---------+---- 1.50 2.00 2.50 3.00 Overall median = 2.30

Mood Median Test: Y versus X2 Mood median test for Y Chi-Square = 0.09 DF = 1 P = 0.761 Individual 95.0% CIs X2 N<= N> Median Q3-Q1 --+---------+---------+---------+---- No 34 35 2.40 4.40 (-------------------*------------) Yes 24 22 2.15 4.10 (--------------*-----------------) --+---------+---------+---------+---- 1.50 2.00 2.50 3.00 Overall median = 2.30

Tollgate Review

D M A I C

X3

Y1

YN

30

25

20

15

10

5

0

Boxplot of Y1 vs X3


X3 – Tool Availability

No difference in either the center (median) or spread (variation) between toolAvailable yes vs. no – not statistical root causeNo difference in either the center (median) or spread (variation) between toolAvailable yes vs. no – not statistical root cause

Mood Median Test: Y1 versus X3 Mood median test for Y1 Chi-Square = 0.00 DF = 1 P = 0.948 Individual 95.0% CIs X3 N<= N> Median Q3-Q1 ---+---------+---------+---------+--- N 7 7 2.35 5.63 (--------*--------------------------) Y 55 53 2.30 4.30 (---*--) ---+---------+---------+---------+--- 1.5 3.0 4.5 6.0 Overall median = 2.30

Mood Median Test: Y1 versus X3 Mood median test for Y1 Chi-Square = 0.00 DF = 1 P = 0.948 Individual 95.0% CIs X3 N<= N> Median Q3-Q1 ---+---------+---------+---------+--- N 7 7 2.35 5.63 (--------*--------------------------) Y 55 53 2.30 4.30 (---*--) ---+---------+---------+---------+--- 1.5 3.0 4.5 6.0 Overall median = 2.30

Test for Equal Variances: Y1 versus X3 95% Bonferroni confidence intervals for standard deviations X3 N Lower StDev Upper N 14 2.12450 3.06088 5.31933 Y 108 3.32853 3.84031 4.52931 F-Test (normal distribution) Test statistic = 0.64, p-value = 0.361 Levene's Test (any continuous distribution) Test statistic = 0.02, p-value = 0.894

Test for Equal Variances: Y1 versus X3 95% Bonferroni confidence intervals for standard deviations X3 N Lower StDev Upper N 14 2.12450 3.06088 5.31933 Y 108 3.32853 3.84031 4.52931 F-Test (normal distribution) Test statistic = 0.64, p-value = 0.361 Levene's Test (any continuous distribution) Test statistic = 0.02, p-value = 0.894

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D M A I C

X4

Y1

YN

30

25

20

15

10

5

0

Boxplot of Y1 vs X4


X4 – Press Availability

The p values are greater than .05; we accept the null hypothesis ~ there isno difference in backorder time when a press is available – yes vs. noThe p values are greater than .05; we accept the null hypothesis ~ there isno difference in backorder time when a press is available – yes vs. no

Mood Median Test: Y1 versus X4 Mood median test for Y1 Chi-Square = 1.11 DF = 1 P = 0.293 Individual 95.0% CIs X4 N<= N> Median Q3-Q1 ---+---------+---------+---------+--- N 22 16 1.65 5.00 (---------*-------------------) Y 40 44 2.40 4.40 (-----------*------------) ---+---------+---------+---------+--- 1.20 1.80 2.40 3.00 Overall median = 2.30 A 95.0% CI for median(N) - median(Y): (-1.70,0.60) Test for Equal Variances: Y1 versus X4 95% Bonferroni confidence intervals for standard deviations X4 N Lower StDev Upper N 38 4.11245 5.18848 6.98004 Y 84 2.47510 2.90730 3.51331 F-Test (normal distribution) Test statistic = 3.18, p-value = 0.000 Levene's Test (any continuous distribution) Test statistic = 0.84, p-value = 0.360

Mood Median Test: Y1 versus X4 Mood median test for Y1 Chi-Square = 1.11 DF = 1 P = 0.293 Individual 95.0% CIs X4 N<= N> Median Q3-Q1 ---+---------+---------+---------+--- N 22 16 1.65 5.00 (---------*-------------------) Y 40 44 2.40 4.40 (-----------*------------) ---+---------+---------+---------+--- 1.20 1.80 2.40 3.00 Overall median = 2.30 A 95.0% CI for median(N) - median(Y): (-1.70,0.60) Test for Equal Variances: Y1 versus X4 95% Bonferroni confidence intervals for standard deviations X4 N Lower StDev Upper N 38 4.11245 5.18848 6.98004 Y 84 2.47510 2.90730 3.51331 F-Test (normal distribution) Test statistic = 3.18, p-value = 0.000 Levene's Test (any continuous distribution) Test statistic = 0.84, p-value = 0.360

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D M A I C

X5

Y1

YesNo

14

12

10

8

6

4

2

0

Boxplot of Y1 vs X5


X5 – Spare Tooling Part Availability

Although the medians appear different, there is not enough data to statisticallyconclude 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 statisticallyconclude there is a difference – there were only six samples when spare tooling was not available

Mood Median Test: Y1 versus X5 Mood median test for Y1 Chi-Square = 0.70 DF = 1 P = 0.401 Individual 95.0% CIs X5 N<= N> Median Q3-Q1 -------+---------+---------+--------- N 2 4 4.30 5.83 (-------------*--------------------) Y 54 52 2.30 4.40 (--*-) -------+---------+---------+--------- 2.5 5.0 7.5 Overall median = 2.35 A 95.0% CI for median(N) - median(Y): (-2.00,9.70) Test for Equal Variances: Y1 versus X5 95% Bonferroni confidence intervals for standard deviations X5 N Lower StDev Upper N 6 2.34663 4.00221 11.4501 Y 106 2.46978 2.85313 3.3707 F-Test (normal distribution) Test statistic = 1.97, p-value = 0.179 Levene's Test (any continuous distribution) Test statistic = 0.52, p-value = 0.472

Mood Median Test: Y1 versus X5 Mood median test for Y1 Chi-Square = 0.70 DF = 1 P = 0.401 Individual 95.0% CIs X5 N<= N> Median Q3-Q1 -------+---------+---------+--------- N 2 4 4.30 5.83 (-------------*--------------------) Y 54 52 2.30 4.40 (--*-) -------+---------+---------+--------- 2.5 5.0 7.5 Overall median = 2.35 A 95.0% CI for median(N) - median(Y): (-2.00,9.70) Test for Equal Variances: Y1 versus X5 95% Bonferroni confidence intervals for standard deviations X5 N Lower StDev Upper N 6 2.34663 4.00221 11.4501 Y 106 2.46978 2.85313 3.3707 F-Test (normal distribution) Test statistic = 1.97, p-value = 0.179 Levene's Test (any continuous distribution) Test statistic = 0.52, p-value = 0.472

Tollgate Review

D M A I C

X6

> 4

95% Bonferroni Confidence Intervals for StDevs

Yes

No

5.04.54.03.53.02.52.0

X6

> 4

Y1

Yes

No

14121086420

F-Test

0.124

Test Statistic 0.67P-Value 0.197

Levene's Test

Test Statistic 2.41P-Value

Test for Equal Variances for Y1

X6 > 4

Y1

YesNo

14

12

10

8

6

4

2

0

Boxplot of Y1 vs X6 > 4


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!!

Mood Median Test: Y1 versus X6 > 4 Mood median test for Y1 Chi-Square = 8.35 DF = 1 P = 0.004 Individual 95.0% CIs X6 > 4 N<= N> Median Q3-Q1 -----+---------+---------+---------+- No 53 40 1.70 3.00 (---*--) Yes 5 17 5.70 4.73 (---------------*-----) -----+---------+---------+---------+- 2.0 4.0 6.0 8.0 Overall median = 2.30

Mood Median Test: Y1 versus X6 > 4 Mood median test for Y1 Chi-Square = 8.35 DF = 1 P = 0.004 Individual 95.0% CIs X6 > 4 N<= N> Median Q3-Q1 -----+---------+---------+---------+- No 53 40 1.70 3.00 (---*--) Yes 5 17 5.70 4.73 (---------------*-----) -----+---------+---------+---------+- 2.0 4.0 6.0 8.0 Overall median = 2.30

Tollgate Review

D M A I C

X7

> 4


Yes

No

4.03.53.02.52.0

X7

> 4

Y1

Yes

No

14121086420

F-Test

0.059


Levene's Test




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

X7 > 4

Y1

YesNo

14

12

10

8

6

4

2

0

Boxplot of Y1 vs X7 > 4

Mood Median Test: Y1 versus X7 > 4 Mood median test for Y1 Chi-Square = 11.72 DF = 1 P = 0.001 Individual 95.0% CIs X7 > 4 N<= N> Median Q3-Q1 -----+---------+---------+---------+- No 22 6 1.00 1.53 (----*---) Yes 36 51 2.70 5.00 (---*--------) -----+---------+---------+---------+- 1.0 2.0 3.0 4.0 Overall median = 2.30

Mood Median Test: Y1 versus X7 > 4 Mood median test for Y1 Chi-Square = 11.72 DF = 1 P = 0.001 Individual 95.0% CIs X7 > 4 N<= N> Median Q3-Q1 -----+---------+---------+---------+- No 22 6 1.00 1.53 (----*---) Yes 36 51 2.70 5.00 (---*--------) -----+---------+---------+---------+- 1.0 2.0 3.0 4.0 Overall median = 2.30

Tollgate Review

D M A I C

X8

Y1

YesNo

14

12

10

8

6

4

2

0

Boxplot of Y1 vs X8


X8 – Orders vs. PullsMood Median Test: Y1 versus X8 Mood median test for Y1 Chi-Square = 0.01 DF = 1 P = 0.928 Individual 95.0% CIs X8 N<= N> Median Q3-Q1 ---+---------+---------+---------+--- No 28 28 2.35 3.55 (----------*--) Yes 30 29 2.30 4.40 (---------------*-----------------) ---+---------+---------+---------+--- 1.40 2.10 2.80 3.50 Overall median = 2.30

Mood Median Test: Y1 versus X8 Mood median test for Y1 Chi-Square = 0.01 DF = 1 P = 0.928 Individual 95.0% CIs X8 N<= N> Median Q3-Q1 ---+---------+---------+---------+--- No 28 28 2.35 3.55 (----------*--) Yes 30 29 2.30 4.40 (---------------*-----------------) ---+---------+---------+---------+--- 1.40 2.10 2.80 3.50 Overall median = 2.30

X8


Yes

No

4.03.53.02.52.0

X8

Y1

Yes

No

14121086420

F-Test

0.273


Levene's Test



No difference in either the center (median) or spread (variation) when we askIf the pull was greater than the order, yes vs. no – not statistical root causeNo difference in either the center (median) or spread (variation) when we askIf the pull was greater than the order, yes vs. no – not statistical root cause

Tollgate Review

D M A I C

(X9)

(Y)

YN

14

12

10

8

6

4

2

0

Boxplot of (Y) vs (X9)


X9 – Low Volume

Mood Median Test: Y1 versus X9 Mood median test for Y1 Chi-Square = 1.01 DF = 1 P = 0.315 Individual 95.0% CIs X9 N<= N> Median Q3-Q1 -------+---------+---------+--------- N 53 53 2.35 4.10 (---*-) Y 9 5 1.85 6.98 (-----*--------------------------) -------+---------+---------+--------- 2.0 4.0 6.0 Overall median = 2.30

Mood Median Test: Y1 versus X9 Mood median test for Y1 Chi-Square = 1.01 DF = 1 P = 0.315 Individual 95.0% CIs X9 N<= N> Median Q3-Q1 -------+---------+---------+--------- N 53 53 2.35 4.10 (---*-) Y 9 5 1.85 6.98 (-----*--------------------------) -------+---------+---------+--------- 2.0 4.0 6.0 Overall median = 2.30

(X9)


Y

N

98765432

(X9)

(Y)

Y

N

14121086420

F-Test

0.282


Levene's Test


Test for Equal Variances for (Y)

No difference in either the center (median) or spread (variation) when we askIf the part is low volume, yes vs. no – not statistical root causeNo difference in either the center (median) or spread (variation) when we askIf the part is low volume, yes vs. no – not statistical root cause

Tollgate Review


X10 – Red Tag or Care

X10

Y1

YesNo

14

12

10

8

6

4

2

0

Boxplot of Y1 vs X10Mood Median Test: Y1 versus X10 Mood median test for Y1 Chi-Square = 1.31 DF = 1 P = 0.253 Individual 95.0% CIs X10 N<= N> Median Q3-Q1 ------+---------+---------+---------+ No 21 15 1.85 4.30 (-----------*-------------) Yes 37 42 2.40 4.40 (----------*------------) ------+---------+---------+---------+ 1.40 2.10 2.80 3.50 Overall median = 2.30

Mood Median Test: Y1 versus X10 Mood median test for Y1 Chi-Square = 1.31 DF = 1 P = 0.253 Individual 95.0% CIs X10 N<= N> Median Q3-Q1 ------+---------+---------+---------+ No 21 15 1.85 4.30 (-----------*-------------) Yes 37 42 2.40 4.40 (----------*------------) ------+---------+---------+---------+ 1.40 2.10 2.80 3.50 Overall median = 2.30

X1


Yes

No

4.254.003.753.503.253.002.752.50

X1

0

Y1

Yes

No

14121086420

F-Test

0.941


Levene's Test



No difference in either the center (median) or spread (variation) when we askIf the material had any pieces in redtag, yes vs. no – not statistical root causeNo difference in either the center (median) or spread (variation) when we askIf the material had any pieces in redtag, yes vs. no – not statistical root cause

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X11 – Start/Stop Part

X12

(Y)

YesNo

14

12

10

8

6

4

2

0

Boxplot of (Y) vs X12

Mood Median Test: (Y) versus X12 Mood median test for (Y) Chi-Square = 3.28 DF = 1 P = 0.070 Individual 95.0% CIs X12 N<= N> Median Q3-Q1 ---+---------+---------+---------+--- No 29 19 1.50 4.60 (-------*--------------------------) Yes 29 38 2.40 4.40 (-----------*---------) ---+---------+---------+---------+--- 1.20 1.80 2.40 3.00 Overall median = 2.30

Mood Median Test: (Y) versus X12 Mood median test for (Y) Chi-Square = 3.28 DF = 1 P = 0.070 Individual 95.0% CIs X12 N<= N> Median Q3-Q1 ---+---------+---------+---------+--- No 29 19 1.50 4.60 (-------*--------------------------) Yes 29 38 2.40 4.40 (-----------*---------) ---+---------+---------+---------+--- 1.20 1.80 2.40 3.00 Overall median = 2.30

X1

2


Yes

No

4.03.53.02.52.0

X1

2

(Y)

Yes

No

14121086420

F-Test

0.476


Levene's Test


Test for Equal Variances for (Y)

No difference in either the center (median) or spread (variation) when we askIf this PN was a start/stop part, yes vs. no – not statistical root causeNo difference in either the center (median) or spread (variation) when we askIf this PN was a start/stop part, yes vs. no – not statistical root cause

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D M A I CAnalyze 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 (X’s) 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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D M A I C 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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D M A I C


Improve / Control Date: 05 / 05 / xx

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D M A I C 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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D M A I C Test Solutions - Pilot

Subsc

ripts


1108

1119

2.52.42.32.22.12.01.91.8Subsc

ripts

Y

1108

1119

2520151050

F-Test

0.000


Levene's Test


Test for Equal Variances for Y

Results for: 1108 vs. 1119

Mood Median Test: Y Mood median test for Y Chi-Square = 60.60 DF = 1 P = 0.000 Individual 95.0% CIs Subscripts N<= N> Median Q3-Q1 +---------+---------+---------+------ 1119 62 150 2.40 2.68 (-------*-----) 1108 789 574 1.40 1.80 (-------* +---------+---------+---------+------ 1.00 1.50 2.00 2.50 Overall median = 1.40 A 95.0% CI for median(1119) - median(1108): (0.60,1.30)

Test for Equal Variances: Y 95% Bonferroni confidence intervals Subscripts N Lower StDev Upper 1119 212 2.01797 2.23877 2.51152 1108 1363 1.82901 1.90766 1.99312 F-Test (normal distribution) Test statistic = 1.38, p-value = 0.001 Levene's Test (any continuous distribution) Test statistic = 16.49, p-value = 0.000

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 medianThe 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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D M A I C New Capability Analysis

Total

1119

1108

Characteristic

1.920

1.370

2.014

ZBench

1.500

1.500

1.500

ZShift

337143

551887

303742

PPM

0.337143

0.551887

0.303742

DPO

0.552

0.304

DPU

1575

212

1363

TotOpps

1

1

Opps

212

1363

Units

531

117

414

Defs

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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D M A I CTimeline for Full Solution Implementation

- Department 11xx was the first module installed.

- Implementation of the remaining modules that will utilize these solutions are as follows:

- Department 11xx will be completely installed by 5/15/xx- Department 11xx will be completely installed by 6/1/xx

- Department 11xx will be completely installed by 8/1/xx

- Department 11xx (Low Volume) will be completely installed by 10/xx

- Department 11xx will be replaced by 11xx (8/1/xx)

- Department 11xx will be replaced by 11xx (6/1/xx)

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D M A I C Financial Impact

- January – April of 200x compared to January – April 200x indicates a reduction in premium of 16%, 80%, 84.5% and 31.4% respectively.

- This equates to a 61.9 % reduction in premium over the same four month period.

- Over the last two months departments without the improvements have accounted for significantly more premium than department 110x.

- Dept 110x Non-Improved Depts- March 18.0 % 52.0 % (1119)- April 27.8 % 58.9 % (1116)

- Our implemented solutions improved our process by 30 %- From 1.4 Sigma to a 2.0 Sigma

- Our implemented solutions reduced our median time to fill a back order by 41.6 %

- From a median of 2.4 to a median of 1.4

- Based on these improvements we conclude that the plant 11 premium will be reduced by approximately 34.0 %

- Based on 200x premium of $308,940, the financial impact will be a reduction in premium of $105,040.00 per year.

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D M A I C Control Plan

- Plant xx team should monitor Maintenance Response Time and tool & Die Repair time.

- This should be monitored on a monthly basis.

- If Maintenance Response Time or Tool & Die Repair Time is greater than 4 hours, plant should investigate root cause

- Need to determine responsible person (s) to monitor these issues

- System generated reports for Maintenance Response Time and Tool & Die Repair Time will support in this effort

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D M A I C Intangibles

- Breaking down “old” barriers and avoiding finger-pointing by using real data collected by a true cross-functional team

- Excellent cross functional team that was represented by manufacturing, PC&L, tool engineer, Quality, IT, Terminal Store Supervisor and Manufacturing & PC&L Master black belts

- Dispelled many theories about causes for premium and allowed us to focus on real root cause

- Provided additional data for the manufacturing team to focus on the real causes for premium and other machine down time / Uptime issues

- Processes across all functions are interrelated but not all controlled by the plant manager

- Good cross functional support is required for the plant to be successful

- Excellent job by IT support to provide accurate real time data.

- Every black belt project should have an IT person on the team

- Excellent data collection and support by all team members.

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D M A I C

Back-up

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D M A I C

$0

$2,000

$4,000

$6,000

$8,000

$10,000

$12,000

$14,000

$16,000

Plant xx- Dept. xxxx Premium in 200x


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D M A I C

$0

$500

$1,000

$1,500

$2,000

$2,500

January Feburary March April

Plant xx- Dept. xxxx Premium in 200x
