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Project Name : Cycle time reduction.Project Owner : s.n. parmar,ajay kumar

choudhari

DMAIC

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Project Progress Overview

D1. Map Project

D2. Approve Project

M1. CTQ Characteristics& Standards

M2. Measurement System Analysis

M3. Data Collection

A1. Baseline Process

A2. Performance Objective

A3. Identify Drivers of Variation

I1. Screen for Vital Xs

I2. Screen for vital Xs

I3. Define Improved Process

C1. MSA on Xs

C2. Improved Process Capability

C3. Establish Control Plan

Key Deliverables: • List of Customer(s) and

Project CTQs• Team Charter• High Level Process Map

(COPIS)• CAP Plan (Optional)• Preliminary CBA, if

applicable

• QFD / CTQ Tree• Operational definition,

Specification limits, target, defect definition for Project Y(s)

• Data Collection Plan• Measurement System

Analysis

• Baseline of Current

Process Performance• Normality Test • Statistical Goal

Statement for Project• List of Statistically

Significant Xs

• List of Vital Few Xs• Transfer Function(s)• Optimal Settings for

Xs• Confirmation

Runs/Results• Tolerances on Vital

Few Xs

• MSA Results on Xs• Post Improvement

Capability• Statistical Confirmation

of Improvements • Process Control Plan• Process Owner Signoff• Final CBA, if applicable

Tollgates:Planned

Completed

03/may/2013 18may/2013 18/d05/2013 27/05/2013 05/06/2013

XXXXXX 15/March/2010 mm/dd/yyyy mm/dd/yyyy mm/dd/yyyy

Steps:

Tools: Survey Focus Groups Interviews ARMI, Stakeholder

Analysis In/Out of Frame Threat vs. Opportunity

Matrix Other ______________

Data Collection Plan Continuous Gage R&R Attribute Gage R&R Sample Size Calculator Other ______________

Basic Statistics Histogram Dot Plots Box and Whisker Plots Run Charts Normality Testing Continuous/Discrete Zst, Zlt Benchmarking Detailed Process Mapping Moments of Truth Nature of Work Flow of Work Fishbone Hypothesis Testing Regression Analysis Other ______________

DOE Pugh Matrix New Process Mapping FMEA on new process Process Modeling /

Simulation Other ______________

Continuous Gauge R&R Discrete Gauge R&R Control Charts Hypothesis Testing CAP Plan Control Plan Other ______________

Define Measure Measure Analyze Analyze Improve Improve Control Control

Overview

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Define

1. Blank2. Project Charter3. Terms and Acronyms Used4. ARMI & Communication Plan/Why not RASIC5. SIPOC6. Process Map

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Customer Sample CommentsKey Output Characteristics

Important to Customer (CTQ's)

Maheh kumar

(CEO)

ABC Ltd.

we are facing our CD manufacturing cycle time

is very high 405 second Instead of 300 second

so we are not achieving Production on time.

Reduce cycle time .

Ajay Kumar choudhari

General manager

ABC Ltd.

Customer not received product on time . Reduce cycle time.

Customer

Define

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In Scope:Quality control.

Out of Scope:All the other process of this organization..

Business Case:ABC Ltd. is the largest optical media manufacturer in the world. We are also manufacturer photo voltaic cell. We make CD /DVD at automation line from raw material (polycarbonate) to final disc in which use of polycarbonate, dye, ml, bonding glue ,silver etc.

First time raw material (polycarbonate ) feeding in moulding m/c after we receive blank substrate disc than disc going for dye coating than coated disc go to dryer for 30 minutes at 90 degree farnhite temp. after than silver coating on the disc for reflectivity . And take one blank substrate disc bonding on dye coated disc.

Problem Statement: Last two months data show that average cycle time 405 second instead of 300 second which is 53% productivity loss from our target and its effect on our customer and profit. .

Goal Statement: I will be reduc the cycle time 405 to 300 second on dated 15 th june 2013.

Project Charter

Milestone

Target Date Actual Date

Start Date

Xxxx

D 03/05/2013

M 10/05/2013

A 18/05/2013

I 27/05/2013

C 05/06/2013

High Level Project Plan

Define

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Definitions:

Indicators Definition

Terms and Acronyms Used Define

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Key Stakeholders Define Measure Analyze Improve Control

Stakeholders-CEO I I I I I

Sponsor-VP A A I A A

Hod of production I i I I I

Quality head I R I I I

BB I A M/A M M

Team Members I R R I I

Message Audience Media Who When

Project Status Leadership E Mail BB Weekily

Tollgate Review VP,BB,HOD PROD.,HOD QUALITY,

E mail conference calls meetings

BB As per project plan

Project Deliverables or Activities MEMBERS

E mail conference calls meetings BB/MEMBER WEEKILY

When Populating the Stakeholder, consider the ARMI:• A= Approver of team decisions• R= Resource or subject matter expert (ad

hoc)• M= Member of team• I= Interested Party who will need to be kept

informed

CommunicationCommunication PlanPlan

Define

ARMIARMI WorksheetWorksheetARMI & Communication Plan

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SIPOC Define

SUPPLIER INPUT PROCESS OUTPUT CUSTOMER

ABC Ltd. Werehouse Raw material (PC) production production

ABC Ltd. Moulding machine Moulding (make blank substract)

production production

ABC Ltd. Dye lab Dye coating on blank substract

production production

ABC Ltd. Disc dryer Dry the disc in the dryer

production production

ABC Ltd. sputter Silver coating on the disc

production production

ABC Ltd. Store/bonding material

One substract disc bond on the dye coated disc.

production production

ABC Ltd. scanner Final scanning. At scanner

production production

ABC Ltd. production Finished disc production Quality

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Measure

1. Data Collection Plan2. Measurement System Analysis3. Process Capability

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Y OperationalDefinition

DefectDefinition

PerformanceStandard

Specification Limit

Opportunity

To reduce cycle time.

Disc cycle time should not be more than 300

seconds.

More then 300 c/s per disc.

300 sec. Usl (300 sec.) weekly

Mode of collecting Data

Y Data Type Unit Decimal to be Used

Data Base Container

Existing or new data

base

If New when data base would be

ready.

Plan start date for DCP

To reduce cycle time

continuous seconds 2 Excel Two month old data

yes 03/05/13

Data Collection Plan

Formula to be used

Data items needed

Equipment Used for

measurement

Equipment Calibration Information

Responsibility

Any Training need

Operator Information

Total production /total time.

Cycle time Timer clockweekly

BB yesMr. mahant

Measure

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Measurement System Analysis

Rule Rule Description Acceptable Result

A R&R % of Tolerance 0.25% ok

B% Contribution (R&R Std deviation)

0 ok

C Number of distinct categories 554 ok

Overall Gage result Ok

Minitab Descriptive Stats

Gage R&R

%ContributionSource VarComp (of VarComp)

Total Gage R&R 0.2 0.00 Repeatability 0.2 0.00 Reproducibility 0.0 0.00

oper 0.0 0.00Part-To-Part 25932.1 100.00Total Variation 25932.3 100.00

Process tolerance = 1

Study Var %Study Var %Tolerance

Source StdDev (SD) (6 * SD) (%SV) (SV/Toler)

Total Gage R&R 0.410 2.458 0.25 245.79

Repeatability 0.410 2.458 0.25 245.79

Reproducibility 0.000 0.000 0.00 0.00

oper 0.000 0.000 0.00 0.00Part-To-Part 161.035 966.208 100.00

96620.76Total Variation 161.035 966.211 100.00

96621.07

Measure

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MeasureMeasurement System Analysis

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Process Capability Measure

since P value <0.05 hence it significant

effect on population.

Data is not normal so that the process Capability is not require so DPMO calculate.

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Measure

DPMO Dpmo = defect per oportunity * 1000000 =0.5349264*1000000 = 5349264

Dpo = total no of defect /total opportunity = 291/544 = 0.5349264

Sigma level =1.40

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1. DCP for Potential Xs2. Identify Potential Xs3. DCP for Potential Xs4. Basic Analysis for Project Y5. Checking for Impact of ...... on Y6. Hypothesis Summary7. MSA results of Impacting Factors

Analyse

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Identify Potential Xs Analyse

Factors identified through brainstorming

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Basic Analysis of Project Y

Normality StudyNormality Study

Randomness & Shape Study

Analyse

Since p -value is less than 0.05, hence the data is not normal.

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Randomness Study Randomness Study Analyse

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AnalyseStability Study Stability Study

P value for Trend is less

than 0.05 so it is significant

impact on my Average cycle

time.

The RUN chart shows that Trends exists in the data while there are no mixture ,oscillation and Clustering . This evidently shows that the data is not stable.

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AnalyseBasic data distrubution Analysis of Project Y

Spread Study Spread Study Central Tendency StudyCentral Tendency Study

Any data on this side is consider as a defect

There is too much variation in the system.

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Basic Analysis of Project YStudy Spread and Central Tendency

Central Tendency StudyCentral Tendency Study

Analyse

Spread Study Spread Study

Range = 990Variance = 74756.70Std deviation = 273.42 IQR = 475.50

Mean = 405.65Median = 336.00

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AnalyseThe

frequency is

deviate

from the

target.so

mean

deviate

hihger side.

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Checking for Impact of ……on Y Analyse

The box plot shows that more then 75% population is below the target of 95%.

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Analyse

Leven test

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Hypothesis Summary

Sl. No. Factor P Value Graphical Tool

Used Inference Next Steps

Age 0.703 Correlations & regration no

Process knowledge 0.847 Correlations & regration no

Age 0.762

levene

no

Team Leader 0.007 yes

trainer 0.121 no

shift 0.922 no

gender 0.762 no

location 0.042 yes

Education 0.429 no

Marital status 0.81 no

Mode of communication 0.547 no

Average cycle time 0.1029 Sign Test for Median No

Summary of Impacting Factors

Analyse

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AnalyseHypothesis SummarySummary of Impacting Factors

Sl. No. Factor P Value Graphical Tool

Used Inference Next Steps

Gender 0.8749

Mann-Whitney Test

No

Education 0.8394 No

Process Complexity 0.5179 No

Location 0.6688 No

Marital Status 0.9813 No

Communication 0.8065 No

Associate Name 0.936 Mood Median Test No

Team Leader 0.508 Mood Median Test No

Process Complexity 0.521 Mood Median Test No

Trainer 0.000 Mood Median Test yes

Shift 0.033 Mood Median Test Yes

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AnalyseVital X’s that are impacting the AvERAGE CYCLE TIME

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MSA Results of Impacting FactorsChecking the Validity of the data of the impacting factors

Sl. No. Factor

MSA Method

UsedResult RCA for

Problems Next Steps

Analyse

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Improve

1. Screening of the Impacting Factors

2. Action Plan for Improving the Factors

3. Basic Analysis of Improved Y

4. Pre–Post Analysis of Project Y

5. Pre-Post Analysis of Factor

6. Improve Summary – Take Aways

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Screening of the Impacting FactorsPrioritize the Impacting Factors

Improve

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Action Plan for Improving the Factors

# Pain Area Root Cause Improvement IdeaImplementatio

n Owner

Implementation Status

Improve

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Basic Analysis of Improved Y

Randomness Study Randomness Study Normality StudyNormality Study

Randomness, Shape , Spread & Centering Study

Spread Study Spread Study Central Tendency StudyCentral Tendency Study

Improve

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Pre-Post Analysis of Project YStatistical Validation of Impact

Graphical DepictionGraphical Depiction Hypothesis ResultHypothesis Result

Inference :Inference :

Improve

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Pre-Post Analysis of Project YStatistical Validation of Impact

Graphical DepictionGraphical Depiction Hypothesis ResultHypothesis Result

Inference :Inference :

Improve

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Pre-Post Analysis of FactorStatistical Validation of Impact

Graphical DepictionGraphical Depiction Hypothesis ResultHypothesis Result

Inference :Inference :

Improve

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Pre-Post Analysis of FactorStatistical Validation of Impact

Graphical DepictionGraphical Depiction Hypothesis ResultHypothesis Result

Inference :Inference :

Improve

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Pre-Post Analysis of FactorStatistical Validation of Impact

Graphical DepictionGraphical Depiction Hypothesis ResultHypothesis Result

Inference :Inference :

Improve

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Pre-Post Analysis of FactorStatistical Validation of Impact

Graphical DepictionGraphical Depiction Hypothesis ResultHypothesis Result

Inference :Inference :

Improve

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Improve Summary – Take Aways Improve

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1. Control Plan & FMEA on Control Plan2. Time Series Study of Y – Pre & Post3. Control Charts & Inference for Y – Pre & Post4. Basic Analysis of Improved Y5. Establish Process Capability6. Control Charts & Inference (for X1)7. Control Charts & Inference (for X2)8. Cost Benefit Analysis and Sign Off

Control

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Control Plan & FMEA on Control Plan

What’s Controlled Goal/Spec Limits Control Method Who/What Measures Where Recorded

Decision Rule /

Corrective Action

SOP

Control

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Time Series Study of Y – Pre & Post Control

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Control Charts & Inference For Y – Pre & Post Control

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Basic Analysis of Improved Y

Randomness Study Randomness Study Normality StudyNormality Study

Randomness, Shape , Spread & Centering Study

Spread Study Spread Study Central Tendency StudyCentral Tendency Study

Control

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Z Bench (Long Term Sigma)

Short Term Sigma(Long Term Sigma +1.5)

Process Capability – Post Implementation

Establish Process Capability Control

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Control Charts & Inference (For X1) Control

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Control Charts & Inference (For X2) Control

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Cost Benefit Analysis & Sign Off

Benefit Source Unit Benefit Units Impacted Total Benefit Cost Reduction

Enhanced Revenues

Labor Reduction

Decreased Overhead

COPQ Cost Reduction

Control

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Indicators Definition

Terms & Definitions Used