For my second project I chose a case study of an automotive manufacturing company. The featured article did a case study on the successful implementation of six sigma DMAIC process along with Beta correction. The authors of the article studied the baseline performance of the process of the automotive manufacturing company, in order to identify the potential causes of the process related problem. They collected various types of data on all the identified potential causes and different types of statistical analysis like regression analysis, hypothesis testing and Taguchi methods were performed in order to identify the main causes. They used Beta correction technique to monitor the process in the control phase. And the results were observed. For …show more content…
So this was identified as the priority area for the organization to focus. The authors and the management decided to address the problem using Six sigma DMAIC, as the cause and the solution of the problem was still unknown. As the part of Define phase, a team was formed with Assistant manager production as the team leader and seven other team members. The team decided to consider the ‘plunger taper’ and ‘foot thickness’ as the critical to quality characteristics. In the measure phase they analyzed the collected data using Minitab software. The total gauge repeatability and reproducibility values were found to be 9.71% and 4.1% respectively, for foot thickness and plunger tape. The results were presented in the paper. As the next step of the measuring phase, p value was determined, and it was less than 0.05. The p-value is the measurement of how likely it is to get the spot data if no real difference existed. Therefore, a small p-value indicates that there is a small chance of getting this data if no real difference existed. For the Analyze phase the team member brain stormed, in order to find the root cause of the problem, they also made cause and effect diagram for variation in plunger taper and variation in foot thickness. While doing the analysis the p value for ANOVA and for the regression grinding stock and Barrel roundness were found to be less than 0.05 which confirmed that these two has a significant impact on plunger taper. During the improve phase the team decided that there is no risk associated with any of the found solutions. So they prepared an implementation plan for all the solutions with details of responsibility and target date for implementation. In the control phase it was made sure that the benefits and knowledge achieved form the six sigma projects are sustained for the long term
The method of Lean Six Sigma is the combination of two business techniques that includes Lean Manufacturing and Six Sigma. Lean manufacturing focuses on improving the flow of the organization by training highly skilled employees to increase the overall speed while Six Sigma focuses on improving current performance and overall accuracy. In most cases, blending both Lean and Six Sigma can be costly; however the end result can have create an organization that focuses on quality, accuracy, and speed to meet the goal which is profitability.
Now, let’s recap a little about Six Sigma and how it operates. This set of quality management tools uses data that reduces defects. The methodology steps in Six Sigma are knowns as: define, measure, analyze, improve, and control. This process is known as the DMAIC system. Each step in this process will help everyone improve the quality of any product. These vital steps make Six Sigma a great tool. Six Sigma achievement happens when the process produces less than 3.4 defects per million opportunities. This quality practice is now used in many companies across the globe.
In the analysis, the hypothesis was that pennies made before 1982 were made out of a different substance than the pennies made after 1982. The hypothesis turned out to be true. The pre 1982 pennies were made out of copper which has a density of 8.6 g/mL and the post 1982 pennies are made out of zinc which has a density of 7.14 g/mL. So it can concur that mass for pennies made before 1982 are higher than pennies made after 1982. Some errors were when calculating. The densities for the pennies and making the graphs. When making the graphs, it can be suspected that each graph is wrong could be wrong due to not adding enough data points or misplaced points. For the data tables , it can also be suspected that the density for each data table could
The 21st century has brought new challenges to manufacturing and service organizations, and one of these important challenges is that the industry is constantly changing (Maleyeff, 2012). Therefore, the systems, processes and procedures of successful businesses will be able to evolve according to the constantly changing industry needs. Six Sigma is one method being widely used by both manufacturing and service businesses today to provide a framework for continuous process improvement (Maleyeff, 2012).
Persoon, T.J., Zaleski, S., & Frerichs, J., (2006) Improving preanalytic processes using the principles of lean production (Toyota Production System). Am J Clin Pathol. 2006 Jan;125(1):16-25.
The project approach utilized the 3NA process and analysis of data by using the PDCA methodology.
The company is also faced with a 20% reject rate that is absolutely unacceptable. A lot of the produced boards go to waste, and a lot of resources are compromised. Moreover, it contributes to the manufacturing strain, as the production team must start with at least 20% more than the required output just to give allowances to the defects. CBF, Inc. should implement a more rigid supervising/monitoring program with the manufacturing processes in order to pinpoint and arrest the cause of these defects.
The Six Sigma approach was designed by Motorola in 1986. The primary objective of the concept was to develop a tool for tallying the process defects and, as the result, improving business operations. The foundations of the approach are the customer needs, statistical analysis of data and facts, and timely execution. The method promises numerous benefits such as increasing performance and profitability of an organization, improving product or service quality and employee morale, decreasing costs, the growth of market share, the higher level of satisfying customer needs, etc. (Meredith & Shafer, 2013). The primary advantage
Secondly, from years of quality control practice the firm established a well-know quality control procedure, "the Method". It has great value to the company in that it includes detail best practices for the production procedures which guarantees and improves the quality of the products. It serves as an efficient decision measure tool and a great training material.
Toyota Motor Manufacturing, U.S.A. (TMM) is deviating from the standard assembly line principle of jidoka in an attempt to avoid expenses incurred from stopping the production line for seat quality defects. This deviation has contributed to the inability to identify the root cause of the problem, which has led to decreased run ratios on the line and an excess of defective automobiles in the overflow lot for multiple days. If this problem isn’t fixed quickly, an increased amount of waste will continue to be incurred and customer value will be threatened.
Nevertheless, I think that the case study method is the best choice for my research question because I am looking for a method to prove an unproven theory. Moreover, case studies are narrowly focused and process-oriented, which I need in order to determine what is the best financial option for startup tech
At the start of the project the problem is defined by the consultant and confirmed by the client. The next step in the consulting process is data collection via a variety of methods. The process of data gathering can be both long and tedious and thus it is essential that consultants attain quality over quality. Some of the most frequently used techniques include group data gathering, interviews, focus groups, surveys, compiling existing documentation and on-site observation. Also some of the common tools used include the STEP analysis- a framework that reviews the external environment by focus on social, technological, environmental and political factors, the SWOT analysis that focuses on the strengths, weaknesses, opportunities and threats relating to the organization, trend analysis and the identification of core competencies.
In this report we want to know how process in manufacturing is done, what they consider in this manufacturing process and different organizations in production process.
Fortunately, during under-graduation, I got an opportunity to detect the optimum path of a process through my project “Design and Development of PCB Dual Head Drilling Machine”. Additionally, I became aware of a new subject called Six Sigma which aided me in intertwining new optimization techniques into my project to make the process effective. I optimized the creation...
Next is the manufacturing where quality analysis will get changed and pose as a great challenge of any product to pass the quality teams norms. This will consume more time and will increase the wastage.