Project Selection, C&E & FMEA

ProjectSelection,C&E&FMEABeltonGroupRexWongBeltonConfidential:Fortrainingonly2SixSigmaTermCTx’s:CT=“CriticalTo…”CTS-CriticalToachievingcustomerSatisfaction.Typically,thisincludes,butisnotlimitedto,thoseparameterswhichareCTQ-CriticaltoQualityCTD-CriticaltoDeliveryCTC-CriticaltoCostSixSigmaLeadsyoutothe“Critical”toIncreasetheEfficiencyoftheImprovementProcess…..WorkonWhatisImportantBeltonConfidential:Fortrainingonly3SixSigmaTermKPOV’s:KeyProcessOutputVariables.TheresultsofthecollectiveactionofKPIV’sinaprocessonaproductTheprocessoutputscriticaltoachievingtheCTX’s,InGolfasanExampleDistancehitordegreesofflinefromteetoholeKPIV’s:KeyProcessInputVariables.Thoseprocessvariablesthatdirectlyand/orinconjunctionwithotherKPIV’s,driveachangeinanoutputvariableClubselection,stance,backswingvelocity,clubfaceangle,wristaction,follow-throughBeltonConfidential:Fortrainingonly4SixSigmaTermProcessBaseline:Theaverage,longtermdefectlevelofaprocesswhenallinputvariablesintheprocessarerunninginanunconstrainedfashionProcessEntitlement:Thebestcase,shorttermdefectlevelofaprocesswhenallinputvariablesintheprocessarecenteredandincontrolProcessBenchmark:ThedefectleveloftheprocessdeemedbycomparisontobethebestprocesspossibleBeltonConfidential:Fortrainingonly5ProcessBaselineProcessBaseline:Theaverage,longtermdefectlevelofaprocesswhenallinputvariablesintheprocessarerunninginanunconstrainedfashionLong-termBaselineBeltonConfidential:Fortrainingonly6ProcessEntitlementProcessEntitlement:Thebestcase,shorttermdefectlevelofaprocesswhenallinputvariablesintheprocessarecenteredandincontrolBeltonConfidential:Fortrainingonly7ProcessBenchmarkProcessBenchmark:ThedefectleveloftheprocessdeemedbycomparisontobethebestprocesspossibleFactoryAFactoryBFactoryCBeltonConfidential:Fortrainingonly8ProjectSelectionWhenyoucreateaGreenBeltproject,youshouldchoosetheprojectinsoftsavingorhard-saving.Hard-saving:Directtoproductcost.Eg,reducescrap,waste,etc.Soft-saving:Indirecttoproductcostbutitwillincreasegroupbenefit.Eg,savelabourhour,reducereworkcost,reduceWIP,reducemaintenancecost,etc.ItisrecommendedtochooseONEKPOVatatime.MultipleKPOVswillincreasethecomplexityoftheprojectandhencelongertimetocompleteproject.Projectshouldcompletewithin2-4monthstypically.Ideally,littleornonewinvestmentisneeded&useexistingresourceswheneverpossible.Itisbestiftheprocessimprovementcanbeappliedtootherproducts.BeltonConfidential:Fortrainingonly9ProjectSelectionProcedure1.Definethetypeofbenefittothegroup(ie,CTx)2.Definetheprocessmetricfromstep1.3.Findoutthebaselinefromtheprocessmetricatleast2week+(typically8weeks).Ifnot,establishwithrelatedfunctionalgroup.Makesurethereisnoshift/driftofyourprocess(ie,stableprocess)4.Locatetheentitlementorbenchmarkoftheprocess.5.Projectshouldofferatargetedreductionoftheprocessmetricby70%orsignificantlyenoughtohaveanimpactonthedefect.6.DiscusswithyourmanagertostartMeasurephaseoftheproject.BeltonConfidential:Fortrainingonly10TrendChartofprojectU6CoilheightDPPMtrendChart48000485004900049500500005050025/4/0228/4/021/5/024/5/027/5/0210/5/0213/5/0216/5/0219/5/0222/5/02DateDPPMBaseline:49946Entitlement:48812Target:4922270%ofyourentitlement=(Baseline–Entitlement)x70%Thedataissimulatedandnotpresentedasactualfigure.BeltonConfidential:Fortrainingonly112TypesofCause&EffectAnalysis1.FishboneDiagram-traditionalapproachtobrainstorminganddiagrammingcause-effectrelationships.Goodtoolwhenthereisoneprimaryeffectbeinganalyzed.2.Cause-EffectMatrix-adiagramintableformshowingthedirectrelationshipsbetweenoutputs(Y’s)andinputs(X’s)BeltonConfidential:Fortrainingonly12Fish-bonediagramTheeffect(KPIV)beinganalyzedisdrawnontherightsideofthechartattheendofalargearrow.Maingroupsofprobablecausesaredrawnasbranchestothearrow.Foreachbranch,allpossiblecausesareidentified.AdvantagesHelpsorganizeandrelatefactorsProvidesastructureforbrainstormingInvolveseveryoneDrawbacksMightbecomeverycomplexRequirespatienceDoesnotrankthecausesinanif-thenmannerMainCategoryCauseSub-CauseRootCauseCausesEffectIssue,ProblemBeltonConfidential:Fortrainingonly13ElementofFish-bonediagramUsually,therearesixelements(6M)forafish-bonediagram:MachinesMeasurementsMenMaterialsMethodsEnvironments(orMilieu)Fish-bonediagramisdevelopedbyteam,ratherthanindividually,asitisbrainstormingprocess.Fish-bonediagramcanbedrawnbyMinitab.BeltonConfidential:Fortrainingonly14ExampleofFish-bonediagramU6TangProfileInspectorTechnicianknowledgeTunneloven(SOP)Normaloven(SOP)CNCm/c(C)E-block(C)Epoxy(SOP)coilthicknesscoilwidthwirediameterwireinsulationslotcuttingreworkingmethod(Cdryingtime(C)dryingtemperaurtebondingtime(C)bondingtemperatureMillingpressuremillingspeedyProjector(SOP)DVTBondingfixturescheckingfixtureOverlayMasterHumidityTemperatureAirFlow(U)Humidity(U)MenMachinesMaterialsMethodsMeasurementsEnvironmentReducethescraprateofU6TangProfilePotentialKPIVsarecategorizedinthebranchesof‘cause’BeltonConfidential:Fortrainingonly15Cause&EffectMatrixCause&EffectMatrix(C&EMatrixorXYmatrix)isusedtofurthernarrowdowntheKPIVsfromfish-