TubeLineWastageReduction(6西格玛)

ReduceWastageofTubeLineFeb.6.2001®TheSignatureofQualityProjectChartDMAICProjectNameReduceWastageofTubelineAffectedProductsBabyDRC,C&CIBT&DPCBand-AidCreamChampionGeorgeZhangMasterBlackBeltRunXia,YangTeamMembersAlanWeng,(MaintenanceSup);AngelTang,(Scheduler);WangWenjie,ZhengXianhong,(Maintenance);Ms.Ma,(Subco.Mgr);LiuXuefeng,WangYiong,CuiRonghua,WangLan(Foreman)StartDateSept.12.2000FinishedDateJan.19.2001Description1.ProjectDescriptionImplementControlPlansinTubelinetoreducethewastageoneachprocess2.ProjectScopeFrommaterialweighing,mixing,fillingtofinishedproductspacking.3.ProjectGoalReduceTubelinematerialwastagefromcurrent35%to10%4.AnnualSavingAnnualsavingsofDRCwillbeover980MRMBin2001basedonnewforecast5.ExpectedBusinessBenefitsDonotneedtoinvestanewtubemachinewhichcostU$180M.6.BenefitstoCustomersSavingsformaterials,improvedproductsqualityandmanufacturingcapability7.Schedule(Keymilestones&dates)MeasureAnalyzeImproveControlSafetyReviewsProjectCompletion/CertificationStartSept.9,2000Sept.20,2000Oct.18,2000Dec.1,2000NA1/2001EndSept.19,2000Oct.17,2000Nov.30,2000Dec.20,2000NA1/2001ProjectChartDMAICTeamMembers•FloraYuanBlackBelt•RunxiaYangMasterBlackBalt•GeorgeZhangChampion•Ms.MoSubcon.Mgr.•AlanWengMaintenanceSup.•AngelTangScheduler.•WangwenjieMechanic•ZhengxianhongElectrician•LiuxufengForeman.•WanglanForeman.•CuironghuaForeman.•WangyiongForeman.•SupportmembersKarolBao,EricShen,HuYumingDMAICVoiceofCustomerFinanceMaterialwastagehighFillingefficiencylowTQAProductsartworknotincenterSubcontractRe-checkqualitywhilepackingPackingefficiencylowHighWastageLowQualityExportproductsrejectedSIPOC&ProcessMapDMAICSupplierInputOutputCustomerWarehouseRawMaterialWarehousePackagingMaterialProductsWarehouseNorden,FrymaMachineUtilityPowerWeighingMixingFillingPackingProcessTQASummaryofDefinePhaseDMAIC•Identifythevoiceofcustomerhelpprojectfocusonkeypoints•Clearlyunderstandtheprojectgoalandscopeareveryimportantforfutureprogress•Processmapanditsinputandoutputhelpteamwellknowtheeachprocess•TeammembersselectionisveryimportantforeachprojectstepPrioritizationMatrixSummaryDMAIC.OutputVariablesArtworkpositionBulkquantityTubesealStrengthEmptyTubeTotalWeight9955HoldSpeed9151120SealTemperature119168ProcessVariablesWayofbulkfed1915120Packingmaterialquality515184Rawmaterialquality151164InputVariablesROwaterweighing1911100FMEASummaryDMAIC.Date:Sept.15,2000(Original)Project:ReducewastageontubelineTeam:LiquidsofJJC(Revised)ItemorProcessStepPotientialFailureModePotentialEffect(s)ofFailureSeverityPotentialCause(s)OcccurrenceCurrentControlDetectionRPNRecommendedActionResponsibilityandTargetDateAfterActionTakenSeverityOccurrenceDetectionRPN1FailtoBulkviscosity8ROwater5Usingflow-720WeighingForemanQualitylowthanspec.highthanspecmeterROwater10/20/20002FailtoMaterialwaste6Tubeartwork5Holder718changespeedMaintenanceCosteccentricspeed120rpmto60rpm10/20/20003FailtoBacteial8Toteshardto2Storein919StoreinstainlessForemanQualityincreasingbecleanbagssteeltotes9/20/20004FailtoOutputlow5Speedlow5Holder212changespeedMaintenanceCostspeed120rpmto60rpm10/20/20005FailtoTubeproduct5Temperature5Temperature515SettemperatureMain.Sup.Costun-seallownospecrange11/30/2000104TotalRsikPriorityNumber=AfterRiskPriorityNumber=FMEAAnalysisDataCollectionPlanOperationalDefinitionandProceduresDataCollectionPlanWhatquestionsdoyouwanttoanswer?DataDataMethodWeighingRelatedconditionsBalanceSamplingNotesHow/whereMixingHowwillyouensureconsistencyandstability?Theplanforstartingdatacollection:DMAIC2.Productsartworkmarkpositionvsholderspeed100%1.BulkbatchquantityvsROwaterMeasureGauge100%Filling1.Prepareworksheet,chartandgaugefordatacollection.2.Trainingcourseforoperatorshowtogetthedata3.DoublecheckthedataWorksheet,Checklist,Controlchart3.FillingyieldvstwowaysbulkfedCountGauge100%FillingGageR&RStudyDMAICObjective:Tubecentermarkeccentricisoneofthespecificationtojudgefinishedgoodscanbereleaseorreject.GageR&Rtestistoensureproductsmeetqualityspecandwegetcorrectdata.Method:Threeoperatorsmeasurefivesamplesthreetimes.Result:•Sampleshavegoodreproducibility•Operatorshavegoodrepeatability•Thestandardnumberofdistinctcategoriesis12.ThemeasurementisgoodGageR&RDMAICTwo-WayANOVATableWithInteractionSourceDFSSMSPUnitnumber417.90584.476440.00000operator20.02180.010890.52574operator*Unitnumber80.12490.015610.00003Repeatability300.06670.00222Total4418.1191StdDevStudyVar%StudyVarSource(SD)(5.15*SD)(%SV)TotalGageR&R0.0817630.4210811.54Repeatability0.0471400.242776.65Reproducibility0.0668050.344059.43operator0.0000000.000000.00operator*Unitnumber0.0668050.344059.43Part-To-Part0.7040233.6257299.33TotalVariation0.7087553.65009100.00Numberofdistinctcategories=12ThestandardNumberofDistinctCategoriesshouldbeover4ThemeasurementisgoodGageR&RforproductsmarkeccentricParetoofOpportunitiesDMAICFillingMixingOtherWeightingPacking050100020406080100Defect•Filling62.8%•Mixing29.5%•Weighing1.4%•Packing1.0%•Other3.0%MostofMateriallostinfillingandmixingprocessDMAICData(Y)Display5060708090100LSLUSLUSLLSLMeanStDev(Within)StDev(Overall)CpCPUCPLCpkPp