Six Sigma Project

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Six Sigma Project
Place the team photograph here
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Organization details
Write briefly about your Organization and
products/services
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D Define
DEFINE
M A Measure Analyse
MEASURE ANALYSE
I Improve
IMPROVE
C Control
CONTROL
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Phase 1- Problem Definition

• Problem Statement
• Part number selected for study
• 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
• 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 RR study required
• Yes / No
• If RR study is required, RR to tolerance

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Phase 1- Problem Definition
Process Mapping
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Phase 1- Problem Definition
Project Planning
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Phase 1- Problem Definition
Photograph of defect part
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Pareto (Based on last 6 months to 1 year data)
Phase 1- Problem Definition
32 of the rejection is due to Blow holes.
Qty produced 27651 nos. Qty scrap 540
nos. Scrap - 1.74 Blow hole scrap
172nos. Blow hole scrap - 0.62
Double click on the graph to update the graph for
your project
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COPQ (Cost of Poor Quality) Calculation
Phase 1- Problem Definition
Note Rejection should include both rework and
scrap
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Phase 1- Problem Definition

• Suspected Sources of Variation for the Problem
  statement (SSVs)

Transfer the above SSVs 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
Tool7
Tool9
Tool3
Tool4
Tool5
Tool2
Tool6
Tool1
Tool8
Legend Tool1 , Tool2
, Tool3 , Tool4
, Tool5 ,Tool6 -
, Tool7 -
Tool8 - , Tool 9 -

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D Define
DEFINE
M A Measure Analyse
MEASURE ANALYSE
I Improve
IMPROVE
C Control
CONTROL
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Phase 2- Measure and Analyze
Analysis 1

• Objective
• Technique/Tool used
• -

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Phase 2- Measure and Analyze
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Phase 2- Measure and Analyze
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Phase 2- Measure and Analyze
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Phase 2- Measure and Analyze
Analysis 1

• Objective
• Conclusion(s)
• -

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Phase 2- Measure and Analyze
Analysis 2

• Objective
• Technique/Tool used
• -

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Phase 2- Measure and Analyze
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Phase 2- Measure and Analyze
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Phase 2- Measure and Analyze
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Phase 2- Measure and Analyze
Analysis 2

• Objective
• Conclusion(s)
• -

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Phase 2- Measure and Analyze
Analysis 3

• Objective
• Technique/Tool used
• -

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Phase 2- Measure and Analyze
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Phase 2- Measure and Analyze
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Phase 2- Measure and Analyze
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Phase 2- Measure and Analyze
Analysis 3

• Objective
• Conclusion(s)
• -

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Phase 2- Measure and Analyze
Analysis 4

• Objective
• Technique/Tool used
• -

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Phase 2- Measure and Analyze
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Phase 2- Measure and Analyze
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Phase 2- Measure and Analyze
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Phase 2- Measure and Analyze
Analysis 4

• Objective
• Conclusion(s)
• -

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Phase 2- Measure and Analyze
Total Analysis summary

• 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
Cause(s) 1
Tool 1
Funneling 1
Cause(s) 2
Funneling 2
Tool 2
Cause(s) 3
Funneling 3
Tool 3
Funneling 4
Cause(s) 4
Tool 4
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D Define
DEFINE
M A Measure Analyse
MEASURE ANALYSE
I Improve
IMPROVE
C Control
CONTROL
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Phase 3 - Improve
Validation of the Root cause(s)
Tool used Data Conclusion
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Phase 3 - Improve
Validation data for Root cause(s)
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Phase 3 - Improve
Analysis of Data for Validation
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Phase 3 Improve Actions Summary
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Phase 3 Improve
Photograph of actions
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Phase 3 Improve
Photograph of actions
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Phase 3 Improve
Photograph of actions
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D Define
DEFINE
M A Measure Analyse
MEASURE ANALYSE
I Improve
IMPROVE
C Control
CONTROL
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Phase 4 Control Phase
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Phase 4- Control
Analysis 1

• Objective
• Tool/technique used

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Phase 4- Control
Data collected for Control
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Phase 4 - Control
Results
Before
After
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Phase 4- Control
Project Summary

• Number of drill downs (funneling) done to reach
  the root 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

• Overall scrap reduced from ---- ppm to ----- ppm
• 2. Defect XXX scrap reduced from --- ppm to
  --- ppm
• Cycle time reduced from ---- seconds to -----
  seconds.
• Estimated cost benefits is Rs. ---------- per
  year.

Intangible benefits derived through the project
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Phase 4 - Control
Current control plan
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Phase 4 - Control
Proposed Control plan