Transcript Six Sigma DMAIC Template

D M A I C
Premium Reduction &
Delivery Improvement
Champion –Sponsor –
Tollgate Review
Contract
D M A I C
Project Title: Premium Reduction
Department
PC&L
Duration
August 2004 - February 2005
Sponsor:
Rachel Heidenreich
Team Members
Function
Total Months: 6
Champion: Marybeth Cunningham
Role
Eric Crump
Ken Dillon
Marne Cario
Chris Kushmaul
Jim Altier
Tom Catheline
William Katko
John Salerno
Donnell Conner
Black Belt Candidate
Green Belt Candidate
Green Belt Re-Certification
Project Coach
Manufacturing Support
Green Belt Candidate
Green Belt Candidate
Green Belt Re-Certification
Green Belt Candidate
PC&L Manager - Project Leader
PC&L Scheduler - Project Leader
PC&L General Supervisor
Master Black Belt
Master Black Belt
Shipping Supervisor
Quality Engineer
Tool Engineer
MFG Supervisor
Customer (internal/external):
internal: PC&L
CTQ addressed:
Premium / IPM (Internal & External)
Business Driver(s) Impacted:
Premium Cost Reduction / IPM Internal And
External Delivery Improvement
Project Scope:
In Scope - Reduction of all Premium from Pt 11
Preliminary Problem Statement:
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%
Aug
Define
actual
Measure
Sep
Oct
Nov
Dec
Jan
Feb
Mar
Apr
Tools Used
Contract / SIPOC / Graphs
`
actual
Process Mapping, Cause and Effect Diagram,
Data collection Plan, MSA
actual
DPMO/Capability, Hypothesis Testing/Root
Cause Analysis
Analyze
Improve
actual
Solution generate, Pilot on Department 1108,
Moods Median Test, Test for Equal Variance
Control
actual
Tollgate Review
Control and Response Plan
$200,000
$180,000
$1
83
,4
11
Plant Premium 200x Detail D M A I C
$160,000
$140,000
$120,000
$100,000
$80,000
$1
24
$6
4
$1
08
$2
00
$7
74
4
4
$1
,2
2
$20,000
$5
,5
8
$40,000
$1
1,
18
1
$1
9,
57
1
$60,000
$0
Behind
Schedule
Internal
Quality
Supplier
Quality
Trans /
Customs
Deliver
Miss
Late Entry Mislabeled Cust. Req /
Inv. Adj
Data was obtained from the Premium Web Site
Tollgate Review
Req /
Inventory
Adj.
Part Cert.
Delay
$250,000
$2
20
,0
19
Plant Premium 200x Detail D M A I C
$200,000
$150,000
$6
59
$3
00
$1
,1
1
0
2
$1
,6
1
0
$1
,8
5
$7
,3
3
$2
0,
49
2
$50,000
8
$100,000
Req /
Inventory
Adj.
Tool
Capacity
$0
Behind
Schedule
Trans /
Customs
Data
Processing
Engineering
Internal
Quality
Deliver Miss
Data was obtained from the Premium Web Site
Tollgate Review
Plant – 200x Internal IPM D M A I C
9,
25
2
10,000
7,
65
5
9,000
8,000
7,000
4,
89
4
6,000
3,
83
4
5,000
2,
89
2
2,
16
9
2,
04
7
3,000
2,
50
7
4,000
0
Jan
Feb March April
0
27
23
9
1,000
26
1
2,000
0
May
June
July
Aug
Sept
Data was obtained from the Premium Web Site
Tollgate Review
Oct
Nov
Dec
YTD
3,500
3,
22
5
Plant 200x – Internal IPM D M A I C
2,
08
9
2,
20
6
2,500
1,
59
6
2,000
1,
97
6
3,000
1,500
50
8
79
9
1,000
24
3
500
0
Jan
Feb
March
April
May
June
Data was obtained from the Premium Web Site
Tollgate Review
July
YTD
SIPOC
Process Name:
Process Owner:
Suppliers
Plant 11 Terminal Manufacturing Process
Plant 11 Premium Reduction Team
Inputs
Process
(Providers of the
required resources)
(Resources required by
the process)
Customer
Forecast
• Pulls
• Orders
PC&L
Production Schedules
Quality
PPAP
Tool Release
Press Release
Part Inspection (PPC)
Manufacturing
Production
Tool Room
• Tool & Die Makers
Tools
Set - UP
Outputs
(Deliverables from
the process)
D M A I C
Customers
(Stakeholders who place the requirements on
the outputs)
Requirements
Parts Shipped on Time
Customer
Requirements
Forecast
• Pulls (Internal)
• Orders (External)
• Scheduling
• Manufacuturing
TERMINALS
Good Quality Parts
Right Quantities
Correctly Labeled
Tool Engineer
Support
Maintenance
Support
Change-over
Terminal Store
Matrial Handling
Shipping
Develop Store Goal
Suppliers
Raw Material
Tollgate Review
SHIP
from
OHIO
INTERNAL
• Mexico
• Mississippi
EXTERNAL
• Lear
• Yazaki
• PS&G
• Condumex
D M A I C
Plant Premium Reduction &
Delivery Improvement
Measure
Date: 01 / 06 / 0x
Tollgate Review
Cause & Effect Diagram
PC&L
Manufacturing
(x) Mtl Movement
Delays
Information Systems
7
(x) Uptime
(x) Lack - Raw
Material
(x) Absenteeism
2
(x) Label
(x) Terminal Store
Picks
(x) Shipping
Patterns
1
(x) Lack - Order Fillers
1
(x) Press
Availability 4
(x) Operator
Training
(x) Scrap
6 Tool Capability
(Goal Changes)
(x) Unforseen
Orders/Pulls
(x) Increased Pulls
2
(x) Goal
Changes
(x)
Defective
Raw
Customer/Supplier
Tollgate Review
5
Labor
Resourcing/Job Ass
Changeover
Time
6
Mtce. Response
Time
6
Spare Tooling
Parts
4
6
Setup Times
(1 - Group w / Un-forcasted orders / pulls?)
(x) Pull Variations
Why do We have
missed/late
shipments?
Spare Equip.
Parts
Tool
3
Availability
6
4
2
(x) Labor
Allocation/Job
(x) Lack - Real
Time Info
(x) Critical Parts List
1
(x) Inventory
Visibility
1
(x) Care Insp.
Coverage
3
(x) Real Time Data
1
(x) Line Insp.
Coverage
(x) Partial Reels
D M A I C
Low Vol. & 4
Obsolete Parts
Make vs Buy
(Note comment from Red Tags?)
(x) FTQ
1
(x) PPAP
(1 - Group with FTQ?)
Issues Running 2
Precious Metal
Unplanned
3
Mtce. Downtime
Eng/Tool Room/Maint.
(x) Red Tags
Quality
3
Should add up to
84
Data Collection Plan
D M A I C
Measure
Data Collection Plan
Time Period
Name of Factor:
Operator (1)
(2)
Trial
Part Number
(Y)
(X1)
(X2)
(X3)
(X4)
(X5)
Joe Bonneau
John Salerno
Joe Bonneau
Ken Dillion
Ken Dillion
John Salerno
Time to fill back
order
Uptime
Set up / Change
Over
Tool
Availability
Press Availability
Spare Tooling Part
Availability
Is an acceptable
press available to
the run part?
The time it takes to
get spare toolign
when parts are not
available
Dicrete
Continuous
Operational Definition
The uptime of the
press while the back
order part number is
in the machine
Type of Data:
Continuous
Specific to:
P/N's
Tollgate Review
Time to convert
good part to good
part
Sitting on
ready rack
Continuous
Discrete
Data Collection Plan
D M A I C
Measure
Data Collection Plan
(Y)
Time Period
(X6)
Joe Bonneau Donnell Conner
Name of Factor:
Operational Definition
Type of Data:
Specific to:
P/N's
Tollgate Review
Operator (1)
(2)
Trial
Part Number
Time to fill back
Maintenance
order
Response Time
(X7)
(X8)
(X9)
(X10)
John Salerno
Marne Cario
Marne Cario
Bill Katko
Tool & Die Response
Time
Unforeseen
Orders / Pulls
Low Volume
Red Tag
Is this part
number low
Volume?
Is this part red
tag or care?
Time from
The difference in time
Difference
when a call is
between when a tool
between the
placed to the has failed & marked on forecast & the
time the work the board & when the
actual pull
is complete
machine is running
Continuous
Continuous
Continuous
Rounded to the hour Build
area
checked
1118
Discrete
Discrete
First time?
Quality?
Gage R & R Study
D M A I C
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)

Appraiser agrees with him / herself trials

Reproducibility
– Between Appraisers

# Inspected
# Matched
% Percent
95.0% CT
30
29
96.7
(82.8 , 99.9)
All appraisers assessments agree with each other
Tollgate Review
D M A I C
Plant Premium Reduction &
Delivery Improvement
Analyze
Date: 03 / 24 / xx
Tollgate Review
Descriptive Statistics
D M A I C
Variable: (Y)
USL = 2 Days
Time a Part is on Backorder (days)
Anderson-Darling Normality Test
A-Squared:
P-Value:
DPMO = 1.4
sigma process
1
4
7
10
13
95% Confidence Interval for Mu
5.269
0.000
Mean
StDev
Variance
Skewness
Kurtosis
N
3.18609
2.89036
8.35419
1.32074
1.59636
115
Minimum
1st Quartile
Median
3rd Quartile
Maximum
0.3000
1.0000
2.3000
5.4000
14.0000
95% Confidence Interval for Mu
2.6522
1.5
2.5
3.5
95% Confidence Interval for Sigma
2.5589
95% Confidence Interval for Median
3.7200
3.3212
95% Confidence Interval for Median
1.6000
2.7000
The median time for parts on backorder is 2.3 days. With a target of 2 days
our process defect rate is 53%
Tollgate Review
Descriptive Statistics
D M A I C
Run Chart for (Y)
14
12
10
(Y)
8
6
4
2
0
10
60
110
Observation
Number of runs about median:
Expected number of runs:
Longest run about median:
Approx P-Value for Clustering:
Approx P-Value for Mixtures:
58.0000
58.4957
10.0000
0.4630
0.5370
Number of runs up or down:
Expected number of runs:
Longest run up or down:
Approx P-Value for Trends:
Approx P-Value for Oscillation:
76.0000
76.3333
3.0000
0.4704
0.5296
Our process is stable with no clustering, mixtures, trends, and oscillations
Tollgate Review
Identify variation Sources
Factor
X1
Name
Press Uptime
Data Type
Analysis Tools
D M A I C
Statistically Significant
Continuous
Simple Linear Regression
Mood's Median Test
Test for Equal Variances
No
Simple Linear Regression
Mood's Median Test
Test for Equal Variances
No
X2
Set Up / Change Over
Continuous
X3
Tool Availability
Discrete
X4
Press Availability
Discrete
X5
Spare Tooling Part
Availability
Discrete
X6
Mantenance Response
Time
Mood's Median Test
Test for Equal Variances
Mood's Median Test
Test for Equal Variances
Mood's Median Test
Test for Equal Variances
No
No
No
Continuous
Simple Linear Regression
Mood's Median Test
Yes - Difference in Center
Test for Equal Variances
X7
Tool & Die Response
Time
Continuous
Simple Linear Regression
Yes - Difference in Center and
Mood's Median Test
variation
Test for Equal Variances
X8
Orders vs. Pulls
Discrete
X9
Low Volume
Discrete
X10
Red Tag or Care
Discrete
X11
Start-Stop Part
Discrete
Tollgate Review
Mood's Median Test
Test for Equal Variances
Mood's Median Test
Test for Equal Variances
Mood's Median Test
Test for Equal Variances
Mood's Median Test
Test for Equal Variances
No
No
No
No
D M A I C
Identify variation Sources
X1 - Uptime
Fitted Line Plot
Y1 = 4.632 - 0.04227 X1
30
S
R-Sq
R-Sq(adj)
25
3.69418
3.7%
2.9%
Regression Analysis: Y1 versus X1 (Uptime)
The regression equation is
Y1 = 4.632 - 0.04227 X1
Y1
20
S = 3.69418
15
R-Sq = 3.7%
R-Sq(adj) = 2.9%
Analysis of Variance
10
Source
Regression
Error
Total
5
0
0
10
20
30
50
40
X1
60
70
80
DF
1
120
121
SS
62.52
1637.63
1700.16
MS
62.5237
13.6470
F
4.58
P
0.034
90
Data analysis shows that machine uptime and time to fill a backorder do not
have a strong correlation – not statistical root cause
Tollgate Review
Identify variation Sources
D M A I C
X2 – Set Up / Change Over
Fitted Line Plot
Y1 = 3.108 + 0.08494 X2
S
R-Sq
R-Sq(adj)
14
12
2.95590
0.7%
0.0%
Mood Median Test: Y speed versus x2 speed
Y1
10
Mood median test for Y speed
Chi-Square = 0.02
DF = 1
8
x2 speed
Long
Short
6
4
2
N<=
10
49
N>
9
47
Median
2.30
2.30
P = 0.899
Q3-Q1
5.60
3.90
Individual 95.0% CIs
----+---------+---------+---------+-(--------*------------------------)
(-----*-)
----+---------+---------+---------+-1.5
3.0
4.5
6.0
Overall median = 2.30
0
0
2
4
8
6
X2
10
12
14
Mood Median Test: Y versus X2
Mood median test for Y
Chi-Square = 0.09
DF = 1
X2
No
Yes
N<=
34
24
N>
35
22
Median
2.40
2.15
Q3-Q1
4.40
4.10
P = 0.761
Individual 95.0% CIs
--+---------+---------+---------+---(-------------------*------------)
(--------------*-----------------)
--+---------+---------+---------+---1.50
2.00
2.50
3.00
Overall median = 2.30
Data analysis shows that Set Up / Change Over Time and time to fill a
backorder have no correlation – not statistical root cause
Tollgate Review
Identify variation Sources
D M A I C
X3 – Tool Availability
Mood Median Test: Y1 versus X3
Mood median test for Y1
Chi-Square = 0.00
DF = 1
Boxplot of Y1 vs X3
30
X3
N
Y
25
Y1
20
N<=
7
55
N>
7
53
Median
2.35
2.30
Q3-Q1
5.63
4.30
P = 0.948
Individual 95.0% CIs
---+---------+---------+---------+--(--------*--------------------------)
(---*--)
---+---------+---------+---------+--1.5
3.0
4.5
6.0
Overall median = 2.30
15
Test for Equal Variances: Y1 versus X3
10
95% Bonferroni confidence intervals for standard deviations
5
X3
N
Y
0
N
N
14
108
Lower
2.12450
3.32853
StDev
3.06088
3.84031
Upper
5.31933
4.52931
Y
X3
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
No difference in either the center (median) or spread (variation) between tool
Available yes vs. no – not statistical root cause
Tollgate Review
Identify variation Sources
D M A I C
X4 – Press Availability
Mood Median Test: Y1 versus X4
Mood median test for Y1
DF = 1
Chi-Square = 1.11
Boxplot of Y1 vs X4
30
X4
N
Y
25
Y1
20
N<=
22
40
N>
16
44
Median
1.65
2.40
Q3-Q1
5.00
4.40
P = 0.293
Individual 95.0% CIs
---+---------+---------+---------+--(---------*-------------------)
(-----------*------------)
---+---------+---------+---------+--3.00
2.40
1.80
1.20
Overall median = 2.30
15
A 95.0% CI for median(N) - median(Y): (-1.70,0.60)
10
Test for Equal Variances: Y1 versus X4
5
95% Bonferroni confidence intervals for standard deviations
0
X4
N
Y
N
N
38
84
Lower
4.11245
2.47510
StDev
5.18848
2.90730
Upper
6.98004
3.51331
Y
X4
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
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
Tollgate Review
Identify variation Sources
D M A I C
X5 – Spare Tooling Part
Availability
Mood Median Test: Y1 versus X5
Mood median test for Y1
Chi-Square = 0.70
DF = 1
Boxplot of Y1 vs X5
14
X5
N
Y
12
N<=
2
54
N>
4
52
Median
4.30
2.30
Q3-Q1
5.83
4.40
10
P = 0.401
Individual 95.0% CIs
-------+---------+---------+--------(-------------*--------------------)
(--*-)
-------+---------+---------+--------2.5
5.0
7.5
Overall median = 2.35
Y1
8
A 95.0% CI for median(N) - median(Y): (-2.00,9.70)
6
Test for Equal Variances: Y1 versus X5
4
95% Bonferroni confidence intervals for standard deviations
2
X5
N
Y
0
No
N
6
106
Lower
2.34663
2.46978
StDev
4.00221
2.85313
Upper
11.4501
3.3707
Yes
X5
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
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
Tollgate Review
Identify variation Sources
D M A I C
X6 – Maintenance Response
Time
Mood Median Test: Y1 versus X6 > 4
Boxplot of Y1 vs X6 > 4
Mood median test for Y1
Chi-Square = 8.35
DF = 1
14
X6 > 4
No
Yes
12
10
8
N<=
53
5
N>
40
17
Median
1.70
5.70
P = 0.004
Q3-Q1
3.00
4.73
Individual 95.0% CIs
-----+---------+---------+---------+(---*--)
(---------------*-----)
-----+---------+---------+---------+2.0
4.0
6.0
8.0
Y1
Overall median = 2.30
Test for Equal Variances for Y1
6
F-Test
4
Test Statistic
P-Value
No
Lev ene's Test
X6 > 4
2
Test Statistic
P-Value
Yes
0
No
Yes
2.0
X6 > 4
2.5
3.0
3.5
4.0
4.5
95% Bonferroni Confidence Intervals for StDevs
5.0
X6 > 4
No
Yes
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!!
0
2
4
6
8
Y1
Tollgate Review
0.67
0.197
10
12
14
2.41
0.124
Identify variation Sources
D M A I C
X7 – Tool & Die Repair Time
Mood Median Test: Y1 versus X7 > 4
Mood median test for Y1
Chi-Square = 11.72
DF = 1
P = 0.001
Boxplot of Y1 vs X7 > 4
X7 > 4
No
Yes
14
N<=
22
36
N>
6
51
Median
1.00
2.70
Individual 95.0% CIs
-----+---------+---------+---------+(----*---)
(---*--------)
-----+---------+---------+---------+1.0
2.0
3.0
4.0
Q3-Q1
1.53
5.00
12
Overall median = 2.30
10
Test for Equal Variances for Y1
8
Y1
F-Test
Test Statistic
P-Value
No
Lev ene's Test
X7 > 4
6
4
Test Statistic
P-Value
Yes
2
2.0
2.5
3.0
3.5
95% Bonferroni Confidence Intervals for StDevs
0
4.0
Yes
No
X7 > 4
X7 > 4
No
Yes
0
2
4
6
8
10
12
14
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
Y1
Tollgate Review
1.02
0.897
3.63
0.059
Identify variation Sources
D M A I C
X8 – Orders vs. Pulls
Mood Median Test: Y1 versus X8
Boxplot of Y1 vs X8
Mood median test for Y1
Chi-Square = 0.01
DF = 1
14
X8
No
Yes
12
N<=
28
30
N>
28
29
Median
2.35
2.30
Q3-Q1
3.55
4.40
10
8
P = 0.928
Individual 95.0% CIs
---+---------+---------+---------+--(----------*--)
(---------------*-----------------)
---+---------+---------+---------+--1.40
2.10
2.80
3.50
Y1
Overall median = 2.30
6
Test for Equal Variances for Y1
F-Test
4
Test Statistic
P-Value
No
2
X8
Lev ene's Test
0
Test Statistic
P-Value
Yes
No
Yes
2.0
X8
2.5
3.0
3.5
95% Bonferroni Confidence Intervals for StDevs
4.0
X8
No
Yes
0
2
4
6
8
10
12
14
Y1
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
Tollgate Review
0.76
0.299
1.21
0.273
Identify variation Sources
D M A I C
X9 – Low Volume
Mood Median Test: Y1 versus X9
Boxplot of (Y) vs (X9)
Mood median test for Y1
Chi-Square = 1.01
DF = 1
14
X9
N
Y
12
N<=
53
9
N>
53
5
Median
2.35
1.85
Q3-Q1
4.10
6.98
(Y)
10
P = 0.315
Individual 95.0% CIs
-------+---------+---------+--------(---*-)
(-----*--------------------------)
-------+---------+---------+--------2.0
4.0
6.0
Overall median = 2.30
8
Test for Equal Variances for (Y)
6
F-Test
4
Test Statistic
P-Value
N
Lev ene's Test
(X9)
2
Test Statistic
P-Value
Y
0
N
2
Y
3
(X9)
4
5
6
7
95% Bonferroni Confidence Intervals for StDevs
8
9
(X9)
N
Y
0
2
4
6
8
10
12
14
(Y)
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
Tollgate Review
0.35
0.007
1.17
0.282
Identify variation Sources
D M A I C
X10 – Red Tag or Care
Mood Median Test: Y1 versus X10
Boxplot of Y1 vs X10
Mood median test for Y1
Chi-Square = 1.31
DF = 1
14
X10
No
Yes
12
N<=
21
37
N>
15
42
Median
1.85
2.40
Q3-Q1
4.30
4.40
10
8
P = 0.253
Individual 95.0% CIs
------+---------+---------+---------+
(-----------*-------------)
(----------*------------)
------+---------+---------+---------+
1.40
2.10
2.80
3.50
Y1
Overall median = 2.30
6
Test for Equal Variances for Y1
4
F-Test
Test Statistic
P-Value
No
Lev ene's Test
X10
2
0
Test Statistic
P-Value
Yes
No
Yes
X10
2.50
2.75
3.00
3.25
3.50
3.75
4.00
95% Bonferroni Confidence Intervals for StDevs
4.25
X10
No
Yes
0
2
4
6
8
Y1
10
12
14
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
Tollgate Review
1.17
0.567
0.01
0.941
D M A I C
Identify variation Sources
X11 – Start/Stop Part
Mood Median Test: (Y) versus X12
Mood median test for (Y)
Chi-Square = 3.28
DF = 1
Boxplot of (Y) vs X12
14
X12
No
Yes
12
N<=
29
29
N>
19
38
Median
1.50
2.40
Q3-Q1
4.60
4.40
10
P = 0.070
Individual 95.0% CIs
---+---------+---------+---------+--(-------*--------------------------)
(-----------*---------)
---+---------+---------+---------+--1.20
1.80
2.40
3.00
(Y)
Overall median = 2.30
8
Test for Equal Variances for (Y)
6
F-Test
4
Test Statistic
P-Value
No
Lev ene's Test
X12
2
Test Statistic
P-Value
Yes
0
2.0
Yes
No
2.5
3.0
3.5
95% Bonferroni Confidence Intervals for StDevs
4.0
X12
X12
No
Yes
0
2
4
6
8
10
12
14
(Y)
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
Tollgate Review
1.49
0.131
0.51
0.476
Analyze Take - Aways
D M A I C
-
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
Tollgate Review
Next Steps
D M A I C
-
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
Tollgate Review
D M A I C
Plant Premium Reduction
& Delivery Improvement
Improve / Control
Date: 05 / 05 / xx
Tollgate Review
Develop Solutions
-
Tool & Die Repair Time Solutions
-
-
D M A I C
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
Tollgate Review
D M A I C
Test Solutions - Pilot
Results for: 1108 vs. 1119
Mood Median Test: Y
Mood median test for Y
Chi-Square = 60.60
DF = 1
Subscripts
1119
1108
N<=
62
789
N>
150
574
Median
2.40
1.40
P = 0.000
Q3-Q1
2.68
1.80
Individual 95.0% CIs
+---------+---------+---------+-----(-------*-----)
(-------*
+---------+---------+---------+-----1.00
1.50
2.00
2.50
Overall median = 1.40
Test for Equal Variances for Y
F-Test
Subscripts
A 95.0% CI for median(1119) - median(1108): (0.60,1.30)
Test for Equal Variances: Y
95% Bonferroni confidence intervals
N
212
1363
Lower
2.01797
1.82901
StDev
2.23877
1.90766
1119
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
1.38
0.001
Lev ene's Test
Test Statistic
P-Value
1108
1.8
Upper
2.51152
1.99312
Subscripts
Subscripts
1119
1108
Test Statistic
P-Value
1.9
2.0
2.1
2.2
2.3
2.4
95% Bonferroni Confidence Intervals for StDevs
16.49
0.000
2.5
1119
1108
0
5
10
15
20
25
Y
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
Tollgate Review
New Capability Analysis
D M A I C
Capability Analysis
Characteristic
Defs
Units
Opps
TotOpps
DPU
DPO
PPM
ZShift
ZBench
1108
414
1363
1
1363
0.304
0.303742
303742
1.500
2.014
1119
117
212
1
212
0.552
0.551887
551887
1.500
1.370
Total
531
0.337143
337143
1.500
1.920
1575
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.
Tollgate Review
Timeline for Full Solution Implementation
D M A I C
-
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)
Tollgate Review
Financial Impact
-
D M A I C
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.
- March
- April
-
Dept 110x
18.0 %
27.8 %
Non-Improved Depts
52.0 % (1119)
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.
Tollgate Review
Control Plan
-
D M A I C
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
Tollgate Review
Intangibles
-
D M A I C
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.
Tollgate Review
D M A I C
Back-up
Tollgate Review
Plant xx- Dept. xxxx Premium in 200x D M A I C
$1
4,
81
4
$16,000
$1
1,
42
0
$14,000
$12,000
$8,000
7
$6
,8
3
$6
,8
3
7
$10,000
6
2
$1
,5
7
$5
12
$1
,5
5
$2,000
$6
78
4
$2
,6
9
$2
,3
8
2
0
$2
,5
8
$4,000
$3
,6
0
2
$6,000
Data was obtained from the Premium Web Site
Tollgate Review
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M
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Fe
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$0
Plant xx- Dept. xxxx Premium in 200x D M A I C
$1
,8
4
7
$2
,1
6
8
$2,500
$2,000
$1
,0
5
6
$1,500
$4
56
$1,000
$500
$0
January Feburary
March
April
Data was obtained from the Premium Web Site
Tollgate Review