六西格玛实施案例

1SIXSIGMAIAMDCTReduce“Dimensional”RejectionsRelatedtoGrindingProcessonPrecisionAerospaceFastenersSixSigmaProjectSonDTran,DirectorofQA,AFS-IndustryOperations2SIXSIGMAIAMDCTDMAICREVIEWDEFINEMEASUREANALYZEIMPROVECONTROLDevelopcharterMaptheprocessUnderstandthevoiceofthecustomerReduceDimensionalVariation-Define3SIXSIGMAIAMDCTProjectOverview:BusinessCaseInternalrejectionsofTitaniumproductscausesignificantscrap,reworkandcustomerreturns.ThislevelofrejectionhasaffectedourKeyPerformanceIndicators(KPI),customerbacklogs,andQualityandDeliveryPerformanceratingstomajorOEM(OriginalEquipmentManufacturer).ReductionofInternalrejectionswillincreasecustomersatisfactionandimproveourKPI.ProblemStatementDimensionalrejectionsrelatedtotheGrindingprocess(es)ofTitaniumHi-LokinCells131,132and133attributedtoabout2%rejectionsoftotalpiecescompleted-to-storethelastsevenmonths(Sep01-Feb02).Thisattributedtomonthlyscraploss,plussignificantrejectionsatsubsequentprocesses(i.e.,ThreadRoll),andincreasedinreworkandcustomerreturnscosts.GoalStatementReducedimensionalrejectionsrelatedtoGrindingprocess(es)inCell131,132&133,by50%fromcurrentFPYbase-lineplusannualreductioninscrapcostof30%endofAugustfiscalyear2002..ReduceDimensionalVariation-Define4SIXSIGMAIAMDCTCustomerNeeds/Requirements●KeyInternalcustomersforWorkCells131,132&133areThreadRollDepartmentandInspection.●ExternalcustomersaremajorOEM.●Customersareexpectingtoreceiveproducts(groundpartsorfinishedparts)thatwillmeetdimensionalspecificationrequirements(orGrind-Defect-Free)everytime.OperationalDefinition-KQC(CTQ)Forthepurposesofthisproject,●GrindDefectsDimensionalcharacteristicsproduceby(oraffectedby)theGrindingprocess(es)ofTitaniumHi-LokinCell131,132&133thatdonotmeetspecifications.ExamplesareGripdiameter,Pre-RollTD,GripLength,etc.ProjectCharterSeeattachedchartsReduceDimensionalVariation-Define5SIXSIGMAIAMDCTProjectCharterGrindDefectsReduction(ReviewedwithSponsorandmanagementteamon3/15/02)ProductImpactedTitaniumHi-LokProductImpactedSales(03proj$)TitaniumBlackBeltSonTranTelephoneNumber626-855-8545ChampionB.FinkenhagenSBU&PlantCOIUnruhStartDate18-Feb-02TargetCompletionDate15-Aug-02ElementDescriptionTeamCharter1.Process:Theproductionprocessinwhichopportunityexists.Grindingprocess(es)onTitaniumHi-Lokhascausedsignificantscrap,reworkandrejectionsatsubsequentprocess(es)(i.e.,ThreadRolldeptwouldreceivesgroundpartswithlargevariationinGripdiaandTDthatwouldcausecharacteristicssuchasMajor/pitchdia,anddifferentialtoexceedspecificationlimits).2.ProjectDescription:DescribetheProject’sPurposeandscope.Improvegrindingprocess(es)thatwouldyield50%reductionindimensionaldefectsonTitaniumHi-lokfromcurrentbase-line3.Objective:WhatimprovementistargetedandwhatwillbetheimpactonFPY,COPQandC-P?BSLGOALENTunits(FirstPassYield)FPY95.697.8%(CostofPoorQuality)COPQ9K+(Scrap)5K$/MoC-Punits/A4.BusinessResults:(incurrentyearDollars)Whatistheimprovementinbusinessperformance(eg-salesandincome)anticipatedandwhen?Reductionofrejectswillreducescrap,reworkandcustomerreturnsthusimprovementtoQualityIndex(KPI)andSupplierPerormanceRating(SPR).Estimatedpaybackis$50KperyearinScraploss.ImproveFPY(dim)to97.8%andSPR99.6%beginningFY’03.5.Teammembers:Whoarethefull-timemembersandanyexpertconsultants?BruceFinkenhagen–Champion,JeffRailton–Coach(BB)SonTran–ProjectLeader,HadyElkobaitry–CI,SandyYaeger–SPC,LarryRainbolt–Engineering,BrentCovan–QualityEngineer.BobAdame–Manufacuring,JohnGonzales–ProcessOwner6.ProjectScope:Whichpartoftheprocesswillbeinvestigated?Grindingprocess(es)onTitaniumHi-LokatWorkCell1337.BenefittoExternalCustomers:Whoarethefinalcustomers,whatbenefitwilltheyseeandwhataretheirmostcriticalrequirements?ExternalOEMcustomers(i.e.,Boeing)anddistributioncenterswillreceiveproductsthatmeetdimensionalspecificationrequirements(less“escapes”)8.Schedule:Givethekeymilestones/dates.ProjectStart18February,2002M-Measurement“M”Completion18March2002A-Analysis“A”Completion30April2002I-Improvement“I”Completion30June2002C-Control“C”Completion30July2002Note:ScheduleappropriateSafetyReviews.SafetyReviewsProjectCompletion08/15/026SIXSIGMAIAMDCTProjectSummary•PurposeReduce“escapes”thusincrease“SupplierPerformanceRating”99.6%Reducescrap,reworkandcustomerreturns.Increaseavenuehencejobretention•Importance•Scope•Measure•ResourcesBruceFinkenhagen-VPOperations-TeamSponsorEdJohnson-SeniorVPQualityAssurance-TeamSponsorSonTran-TeamLeaderBrentCovan-QualityEngineerLarryRainbolt-ManufacturingEngineerBobAdame-GrindingTeamLeadHadyElkobaitry-ContinuousImprovementManager(BB)SandyYaeger-SPCManager(BB)JohnGonzales-ManufacturingManagerGrindingProcessesofTitaniumHi-LockatWorkCell133Improvemachinecapabilitywithno“major”capitalinvestmentexpenditureDefect=DimensionalcharacteristicsthatdonotmeetspecificationsGoal=Reduce50%dimensionaldefectsatGrindingfromcurrentFPYbaselineImprovemachinecapabilitybyidentifyingthemajorprocesselement(s)throughdatacollectionandprocessanalysis,thenestablishandmaintainprocessparameterstocontroltheprocess.Completein(6)month•DeliverablesReduce“Dimensional”Rejecti