Six Sigma Black Belt Project Example
Six Sigma Black Belt Project Example
Six Sigma Black Belt Project Example
This work is to fulfill the Final Project requirement for the Aveta Certified Six Sigma Black Belt Program
Versin 1.0
Pgina 2
Problem Description
Managing over one hundred SKUs, as well as having a geographically diverse supply chain create many challenges in inventory management. The company has experienced in several instances stock outs. Unexpected shortages of stock as well as having a backlog in order fulfillment are more than merely a nuisance. The market in which Tecnomed operates is highly competitive. Oftentimes a customer may not be willing to wait for the order to be fulfilled longer than 24 hours. Management may at times choose to incur extra expense to expedite shipments of stock-out items. In other instances the sales force may be obliged to grant a customer a significant discount as a way to prevent the loss of sale due to stock-out. In either scenario the company incurs in unexpected liability. The current inventory management system that the company uses has a minimum stock level alert. This is however a static/determinist quantity, which is seldom if ever updated. To date, the company has not performed a detailed study of the stochastic nature of demand and transport times. The Black Belt Project will address the area of stock-outs and will aim to minimize its impact on companys finances as well as in customer satisfaction.
Versin 1.0
Pgina 3
Project Budget
Given that this is an analytically-driven project, the principal resource involved is time allocation of members of the Six Sigma team. To a lesser extent, time availability for interviewing of operators and logisticians is also a resource. We dont expect our recommendations to include considerable capital expenditures. Rather, we expect our recommendations to include changes in purchasing and logistics heuristics, procedures and practices. Therefore, we do not try to quantify a monetary budget. The time allocation of the people resources involved is detailed in the WBS/Schedule chart.
Versin 1.0
Pgina 5
We discussed these findings with our management contact. Based on her personal and anecdotal experience, she agrees that this prioritization is correct. The industry and markets in which the company operates have several sophisticated competitors. The customer is highly price-sensitive but also expects quick delivery times. Package quality is not a major differentiator given that governmental regulations norm strictly the design of packaging. Customer service practices are very important to the client. However, customer practices have become relatively standardized in this industry. Therefore all main competitors have similar customer service practices and levels in the industry.
Inventory Carrying Cost.- Carrying inventory involves a hard cost. Not only does inventory signifies a capital expenditure (and therefore interest expense) but also warehousing, handling and insurance costs. We include this cost into our consideration because recommendations on increased buffer or safety stock do imply an incremental inventory carrying expense that has to be justified by reductions in stock-out costs. Critical to Schedule:
Versin 1.0
Pgina 6
Versin 1.0
Pgina 7
SKU-Daily Demand (D)ALBENDAZOL 400 MG X 100 COMPRIMIDOS V-5 MULTIVITAMINAS X 140 UNID S. NARANJA V-5 MULTIVITAMINAS X 140 UNID S.FRUTILLA GLIBENCLAMIDA 5 MG X 100 COMPRIMIDOS CREMA CURATIVA DR. SELBY 5 GR. CREMA CURATIVA DR. SELBY X 20 GR. KETOCONAZOL CREMA AL 2% X 30 GR SALBUTAMOL INHALADOR COMPLEJO B X 10 AMP CIPROFLOXACINA 200 MG X 1 FCO AMP METOCLOPRAMIDA 10 MG X 10 AMPOLLAS CREMA CURATIVA DR. SELBY 40 GR. (D)OMEPRAZOL 40 MG + SOLVENTE METRONIDAZOL 500 MG INYECTABLE UP.VITAMINA K 10 MG/1ML X 1 AMP AGUA CON LIDOCANA AL 1% X 5 ML X 1 Amp METAMIZOL INY 1G 2ML X 1 AMP VITAMINA C 1 GR. X 1 AMPOLLA UP.DEXAMETASONA 4 MG X 1 AMP AGUA DESTILADA 5 ML X 1 AMP
Mean StdDev 2.36 2.70 2.89 4.90 5.53 1.88 14.06 13.18 15.98 2.87 17.90 5.19 18.29 21.22 29.08 5.89 34.50 4.14 39.16 39.24 40.31 4.56 46.53 1.70 66.19 14.90 84.63 18.71 189.06 35.98 250.00 31.54 360.40 33.23 575.00 147.81 606.67 55.22 966.67 129.43
Delivery Times We took a sample of delivery times occurred over the span of 20 weeks. The process of data gathering was manually done due to the fact that the company does not keep automated records for this variable currently. We determined duration from purchasing request and delivery form dates. The sample rendered a fairly normally distributed variable.
Versin 1.0
Pgina 8
Inventory Carrying Cost The companys accounting department does maintain an estimated inventory carrying cost. It takes into account warehousing, labor, insurance and interest expenses allocated using SKU cost as basis. The calculation is updated on an annual basis. While by Accountings own admission this calculation is an estimate, we make use of it given that management is used to it and validating this indicator is out of scope for our project. The number that the company uses is 6% of retail value.
Versin 1.0
Pgina 9
Versin 1.0
Pgina 10
Where:
And:
In basic terms, this model states that the stock-out cost for a given SKU is an expected value. Its derived from multiplying the probability of a stock-out times the weighted average cost of a stockout. The probability of a stock-out is the same as the probability of demand exceeding certain value (our determined safety stock). This is readily calculated given that we have previously determined mean and standard deviation for each SKU studied. Using the probabilities and costs for each case of a stock-out, we can readily determine the weighted average cost of a stock-out. We determine this to be 16% of retail price.
Where: D = Mean Daily Demand SKU L = Mean Replenishment Lead Time in Days Z = Service level we want to achieve And:
This is the standard formula for variance for the product of two independent variables.
Versin 1.0
Pgina 12
DECREASES
AS
INCREASES
Where:
This takes into account the cost of carrying stock in excess of the expected demand And:
Versin 1.0
Pgina 13
Based on the preceding model, we derive the following conclusions: The cost of offering service levels greater than 90% quickly rises and outweighs the cost suffering stock-outs. Getting a more reliable carrier (i.e. less variability) does not make a decisive impact on total costs. Demand variability (i.e. demands standard deviation) and consequently Safety Stock requirements, has greater impact on total costs. All things being equal, getting a supplier located geographically closer, such that Lead Times are reduced, does have a significant impact on total costs.
Criteria Do Nothing Increase SS to 80% Increase SS to 90% Increase SS to 99% Find Local Supplier Find Reliable Carrier
Cost Base S + S S
Based on our comparative analysis, we recommend the following managerial on operative adjustments to the companys business processes: Set reorder points to no greater than a 90% service level. Continue offering discounts to those customers who otherwise may not wait. Analyze if better service times can be negotiated with the supplier, or if the company can find suppliers closer to its warehouse.
Furthermore we suggest topics for further study: Determine if customers are equally sensitive to stock-outs in all SKUs or if theres a differentiation. This could allow setting lower service levels to less sensitive SKUs. Determine the causes that drive demand variability and if the company can do anything to smooth demand or better predict it.
We include a table estimating Safety Stock for all 20 SKUs in our study on the Appendix section. During our analysis we have done detailed flowcharts and Value Stream Mapping on the companys replenishment business processes. We also referred to commonly process improvement methodologies such as Lean Manufacturing and Japanese 5-S methodologies. We detail additional findings and recommendations below.
Versin 1.0
Japanese 5-S
Sorting.- We have previously noted that out of the 170 SKUs, 20 are responsible for over 70% of sales volume. Therefore, its warranted to differentiate the level of attention to inventory levels according to their criticality and volume. Straightening.- We witnessed that the inventory keeping system does suffer from some inaccuracies. As the arithmetic in the engine has been proven as accurate, we believe the source of errors is in the data entry process. We recommend that the company investigate the causes of inventory data mis-keys. Shine.-Inventory keeping errors made in the past have a compound effect in SKU count. Make a priority cleaning up inventory system data. Standardize.- Setting up consistent service levels and reorder points helps better communicate managerial performance expectations for the replenishment process. Sustaining.- Documenting and training the relevant operators will ensure that the changes will persist through time. Furthermore we recommend that service level data be included in the companys Balanced Scorecard Report.
Versin 1.0
Pgina 16
Versin 1.0
Pgina 17
Versin 1.0
Pgina 18
Price Speed of Delivery Packaging Quality Customer Service Sum Price Speed of Delivery Packaging Quality Customer Service Factor Price Speed of Delivery Packaging Quality Customer Service
Versin 1.0
Pgina 19
Versin 1.0
Pgina 20
Versin 1.0
Pgina 21
Versin 1.0
Pgina 22
Versin 1.0
Pgina 23
SKU-Daily Demand (D)ALBENDAZOL 400 MG X 100 COMPRIMIDOS V-5 MULTIVITAMINAS X 140 UNID S. NARANJA V-5 MULTIVITAMINAS X 140 UNID S.FRUTILLA GLIBENCLAMIDA 5 MG X 100 COMPRIMIDOS CREMA CURATIVA DR. SELBY 5 GR. CREMA CURATIVA DR. SELBY X 20 GR. KETOCONAZOL CREMA AL 2% X 30 GR SALBUTAMOL INHALADOR COMPLEJO B X 10 AMP CIPROFLOXACINA 200 MG X 1 FCO AMP METOCLOPRAMIDA 10 MG X 10 AMPOLLAS CREMA CURATIVA DR. SELBY 40 GR. (D)OMEPRAZOL 40 MG + SOLVENTE METRONIDAZOL 500 MG INYECTABLE UP.VITAMINA K 10 MG/1ML X 1 AMP AGUA CON LIDOCANA AL 1% X 5 ML X 1 Amp METAMIZOL INY 1G 2ML X 1 AMP 2 3 6 14 16 18 18 29 35 39 40 47 66 85 189 250 360 575 607 967 15 19 36 32 33 148 55 129 2 5 202 233 331 423 945 1,250 1,802 2,875 3,033 4,833 39 196 6 4 145 173 846 1,190 1,534 1,625 2,165 4,381 7,162 35,745 62,500 129,888 330,625 368,044 934,444 21 91 335 5 89 320 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 3 80 255 4 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 13 70 198 4 25 2 28 31 4 25 4 174 8 27 450 35 17 1,540 21 3 222 350 1,295 995 1,105 21,847 3,050 16,752 5 14 8 4 25 24 3 12 6 4 25 7 207 638 225 5,225 1,342 2,099 12,745 4,632 5,728 45,325 7,755 9,711 25,052 40,635 191,509 303,125 605,889 2,018,156 1,714,809 4,579,050 VITAMINA C 1 GR. X 1 AMPOLLA UP.DEXAMETASONA 4 MG X 1 AMP AGUA DESTILADA 5 ML X 1 AMP
Mean
StdDev
DxL
E(D)^2
Var(L) E(L)^2
Var(D)
Var(DL)
Std. Dev (DL) 14 25 15 72 37 46 113 68 76 213 88 99 158 202 438 551 778 1,421 1,310 2,140
Z(90%) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Reorder Point
Safety Stock
30
18
72
58
77
49
380
309
273
193
377
288
913
822
709 875
564 702
2,385
2,189
1,195
994
1,443
1,210
2,433
2,102
3,302
2,879
7,633
6,687
10,214
8,964
15,254
13,452
28,846
25,971
48,233
43,400
Versin 1.0
28,283
25,249
Pgina 24
Versin 1.0
Pgina 25