Six Sigma Project

Six Sigma

Organization Name Place the team

Plant Location photograph here
Name of the Black Belt
Team Members

Date of Start
 Organization details
Six Sigma

Write briefly about your Organization and

products/services
 D
DEFINE
Six Sigma

Define

M&A
Measure &
MEASURE & ANALYSE
Analyse

I
Improve
IMPROVE

C
Control
CONTROL

3
 Phase – 1- Problem Definition
• Problem Statement
–
• Part number selected for study
Six Sigma

–
• Other similar part numbers having the problem
–
• Process stages where the Problem is detected
–
–
–
• Current average rejection for last 6 months
–
• Maximum and Minimum rejection in last 6 months
– Maximum rejection in a month -
– Minimum rejection in a month -

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 Phase – 1- Problem Definition
• Number of lines/presses/machines used for processing
–
Six Sigma

• Objective of the Project

–
• Annual Savings in Rs. Lakhs if the defect is made zero and
horizontally deployed to other part numbers
–
• Response
– Variable / Attribute
• Specification (if the response is variable)
–
• Is R&R study required
– Yes / No
• If R&R study is required, % R&R to tolerance
–

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 Phase – 1- Problem Definition
Process Mapping
Six Sigma

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 Phase – 1- Problem Definition
Project Planning
Month Month Month
Phase
W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4
Six Sigma

Define

Measure &
Analyze

Improve

Control

Phases Planned Planned Actual start Actual Status

Start date Completion date completion
date date
Define

Measure &
Analyze
Improve

Control

7
 Phase – 1- Problem Definition
Photograph of defect part
Six Sigma

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 Phase – 1- Problem Definition
Pareto (Based on last 6 months to 1 year data)
Six Sigma

Def ectw ise pareto analysis f or Product XXX - Jul - Jan

99% 100% 100%
100%
500 82% 90%
80%

Contribution in %
400
Scrap in nos.

60% 70%
60%
300
32% 50%
200 172 40%
148
118 30%
90
100 20%
2 1 10%
0 0%
Blow holes Nonfilling Mixup Surf ace Setup scrap Crack
damages
Def ect

32% of the rejection is due to Blow holes. Qty produced: 27651 nos.
Qty scrap – 540 nos.
Scrap % - 1.74
Double click on the graph to update the graph for your project Blow hole scrap – 172nos.
Blow hole scrap % - 0.62
 Phase – 1- Problem Definition
COPQ (Cost of Poor Quality) Calculation
Number of pieces rejected last
month (for the part number
Six Sigma

identified for study)

Number of pieces scrapped last
month
Number of pieces reworked last
month
Scrap cost/piece
Rework cost/piece
Total scrap cost (Rs. Lakhs) for last
month
Total rework cost(Rs. Lakhs) for last
month
Total Rejection cost (Rs. Lakhs) for
last month
Extrapolated Total rejection cost
(Rs.should
Note: Rejection Lakhs) for one
include bothyear
rework and scrap
 Phase – 1- Problem Definition
• Suspected Sources of Variation for the Problem statement
Six Sigma

(SSV’s)

Transfer the above SSV’s to the next slide, write the tools you have used in the column and identify which tool has been used for which
cause. Also write the name of the tool in the Legend

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 Phase – 1- Problem Definition

Tool#9
Tool#7
Tool#3

Tool#4

Tool#5
Tool#2
SSV’s

Tool#6
Tool#1

Tool#8
Six Sigma

Legend: Tool#1 – , Tool#2 – , Tool#3 – , Tool#4 – , Tool#5 – ,Tool#6 - , Tool#7 -

Tool#8 - , Tool #9 -

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 D
DEFINE
Six Sigma

Define

M&A
Measure &
MEASURE & ANALYSE
Analyse

I
Improve
IMPROVE

C
Control
CONTROL

13
 Phase – 2- Measure and
Analyze
Analysis # 1
Six Sigma

• Objective:

•Technique/Tool used:
-

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 Phase – 2- Measure and
Analyze
Six Sigma

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 Phase – 2- Measure and
Analyze
Six Sigma

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 Phase – 2- Measure and
Analyze
Six Sigma

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 Phase – 2- Measure and
Analyze
Analysis # 1
Six Sigma

• Objective:

•Conclusion(s):
-

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 Phase – 2- Measure and
Analyze
Analysis # 2
Six Sigma

• Objective:

•Technique/Tool used:
-

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 Phase – 2- Measure and
Analyze
Six Sigma

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 Phase – 2- Measure and
Analyze
Six Sigma

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 Phase – 2- Measure and
Analyze
Six Sigma

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 Phase – 2- Measure and
Analyze
Analysis # 2
Six Sigma

• Objective:

•Conclusion(s):
-

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 Phase – 2- Measure and
Analyze
Analysis # 3
Six Sigma

• Objective:

•Technique/Tool used:
-

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 Phase – 2- Measure and
Analyze
Six Sigma

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 Phase – 2- Measure and
Analyze
Six Sigma

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 Phase – 2- Measure and
Analyze
Six Sigma

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 Phase – 2- Measure and
Analyze
Analysis # 3
Six Sigma

• Objective:

•Conclusion(s):
-

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 Phase – 2- Measure and
Analyze
Analysis # 4
Six Sigma

• Objective:

•Technique/Tool used:
-

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 Phase – 2- Measure and
Analyze
Six Sigma

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 Phase – 2- Measure and
Analyze
Six Sigma

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 Phase – 2- Measure and
Analyze
Six Sigma

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 Phase – 2- Measure and
Analyze
Analysis # 4
Six Sigma

• Objective:

•Conclusion(s):
-

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 Phase – 2- Measure and
Analyze
Total Analysis summary
Six Sigma

• Cause(s) identified for the problem:

• Root cause(s) identified for the problem:

-

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 Phase – 2 – Measure and
Analyze
Funneling Summary

Funneling :
Six Sigma

Cause(s) # 1
Funneling #1 Tool # 1

Funneling # 2 Tool # 2 Cause(s) # 2

Funneling # 3 Tool # 3 Cause(s) # 3

Funneling # 4 Cause(s) # 4
Tool # 4

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 D
DEFINE
Six Sigma

Define

M&A
Measure &
MEASURE & ANALYSE
Analyse

I
Improve
IMPROVE

C
Control
CONTROL

36
 Phase – 3 - Improve
Validation of the Root cause(s)
Tool used:
Six Sigma

Data:

Conclusion:

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 Phase – 3 - Improve
Validation data for Root cause(s)
Six Sigma

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 Phase – 3 - Improve
Analysis of Data for Validation
Six Sigma

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 Phase – 3 – Improve – Actions
Summary
No Root cause(s) Actions Planned Planned Resp Actual Status
Completion completio
Six Sigma

date n date

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 Phase – 3 – Improve
Photograph of actions
Six Sigma

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 Phase – 3 – Improve
Photograph of actions
Six Sigma

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 Phase – 3 – Improve
Photograph of actions
Six Sigma

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 D
DEFINE
Six Sigma

Define

M&A
Measure &
MEASURE & ANALYSE
Analyse

I
Improve
IMPROVE

C
Control
CONTROL

44
 Phase – 4 – Control Phase
No Root cause Variation Type of Status of
analysis done control implementation
Six Sigma

method
decided

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 Phase – 4- Control
Analysis # 1
• Objective:
Six Sigma

•Tool/technique used:
-

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 Phase – 4- Control
Data collected for Control
Six Sigma

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 Phase – 4 - Control
Results
Before After
Six Sigma

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 Phase – 4- Control
Project Summary

• Number of drill down’s (funneling) done to reach the root

Six Sigma

cause(s):
•Number of predominant root cause(s) identified:
•Time in months for completing the project:
•Tools/Techniques used:

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 Phase – 4 - Control
Tangible Benefits derived through the project
Six Sigma

1. Overall scrap reduced from ---- ppm to ----- ppm

2. Defect XXX scrap reduced from --- ppm to --- ppm

3. Cycle time reduced from ---- seconds to ----- seconds.

4. Estimated cost benefits is Rs. ---------- per year.

Intangible benefits derived through the project

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 Phase – 4 - Control
Current control plan
Six Sigma

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 Phase – 4 - Control
Proposed Control plan
Six Sigma

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