6西格玛黑带项目案例

Climate Controls OEM Products GroupReduce Returns of 24245SIX SIGMA BLACK BELT PROJECT CANDIDATE: PETER WRIGHT CHAMPION: KEVIN KIDDERSTART FEBUARY 18, 2002 ESTIMATED COMPLETION JULY 15, 2002Define Section1Climate Controls OEM Products GroupDefine ProjectDMAIC REVIEWCONTROLDEFINEIMPROVEMEASUREANALYZEDevelop charter Map the process Understand the voice of the customerDefine Section 2Climate Controls OEM Products GroupSIPOC Suppliers – Inputs – Process – Outputs - CustomersSuppliers24221 Raw CastingInputsProcessReceive Inspect Raw CastingOutputsCustomersChina Precision 24245 Modern MetalMachine Main Valve SeatAcceptable 24245MexicaliTexas Die CastingInspect Main Valve SeatMeasure Section3Climate Controls OEM Products GroupProject Overview : Customer is frustrated by failures due to the Main Valve Seat defects. • 2% Rejects 20,000 assemblies - 400 rejects daily. • Excessive rework to main valve seat. • Excessive returns to the Long Beach.Define Section4Climate Controls OEM Products GroupExecutive Summary: Reduce the Main Valve Reworks/Returns Create a process that is 1.67 Cpk capableDefine Section5Climate Controls OEM Products GroupGoal: • Reduce current 24245 PPM Returns to < 500 PPM • Savings to Mexicali $25,000 annually • Savings to Long Beach $ 40,000 annuallyProjected Improvement: • Reduce failures during Mexicali Assembly and test • Create more robust machining and inspection of the main valve seatDefine Section 6Six Sigma: TEAM CHARTERProduct Impacted Blackbelt X Greenbelt Champion Start Date Element 1. Process / Product: 2. Project Description: 3. Objective:110 BodyClimate Controls OEM Products GroupPeter Wright Kevin Kidder Feb. 18, 2002 Description The production process in which opportunity exists. Describe the Project’s Purpose and scope.What improvement is targeted and what will be the impact on RTY, COPQ and C-P? Quality Metrics: RTY, DPU, DPPMProduct Impacted Sales (’03 proj $) Telephone Number SBU & Plant Target Completion Date Team Charter1-310-900-2395 Water Heating 30 Sep 2002Kingsbury main valve machining. Machining defects on main valve resulting in leaking of main valve seat. To reduce the Defects on the main valve seat for Part Number24245.Base lineQualityActualGoalProject Charter 24245 Main Valve SeatEntitl ement .1%unitsSee attached Definition sheet for examplesRTY 2% 2% $65k .2% $65k $2.5k $1.25k dollarsCost of P oor Quality4. Business Results: What is the improvement in (in 2000 Dollars) business performance (egsales and income) anticipated and when? 5. Team members: Who are the full-time members and any expert consultants? 6. Project Scope: 7. Benefit to External Customers: 8. Schedule: Focus on projects that can be finished In 4-6 months max. Which part of the process will be investigated? Who are the final customers, what benefit will they see and what are their most critical requirements? Give the key milestones/dates. M- Measurement A- Analysis I- Improvement C- Control Note: Schedule appropriate Safety Reviews.COPQReduction of the rejects at Mexicali will result in less disassembly higher RTY, thus a reduction in the COPQ due to this defect. Estimated payback for the two plants is $62.5k per year, effective Fiscal year 2003.Kevin Kidder – Champion Leonel Garcia – Customer Ricardo Partida – Quality Engineer 110 Line Main Valve Seat 24245 Rheem, American Water Heating benefit will be longer life and less returns due to leaking on gas from the main valve seat.Project Start2/15/20023/15/2002 “M” Completion “A” Completion 4/15/2002 “I” Completion 6/15/2002“C” Completion 7/15/2002 Safety Reviews Project Completion 8/15/20029. Support Required:Will you need any special capabilities, hardware, etc?Define SectionNew machine for machining the main valve seat. New optical inspection equipment for inspecting the dimension and defects in the main valve seat area.7Climate Controls OEM Products GroupMeasure ProjectDMAIC REVIEWCONTROLDEFINEIMPROVEMEASUREANALYZEData Collection Process SigmaData Analysis Process AnalysisDefine Section 8Climate Controls OEM Products GroupDamaged Main Valve SeatAcceptable Main Valve SeatMeasure Section 9Climate Controls KPIVs Measurement OEM Products GroupKPOVsStartRTY Drawing Work instructions SOP MicroscopeParts Machined in Long BeachOK? YNScrap/Rework PartsScrap $$ Process Cpk QuantityWork instructionsSOP MacPacPackage & Ship NRight P/N ? Right Address?Ass’y drawing Work instructions Ass’y drawing Work instructions Ass’y drawing Work instructionsSOP MicroscopeOK? Y Assembly & TestReturn to Long BeachPPM RTY $$ returnedSOPRTYSpecification SOPOK? YNReturn to Long BeachCycle time Reject rate Scrap $$$Measure Section110Climate ControlsOEM Products GroupPackage andOK?YClimate ControlsF u g a e x t e r n aF . v a l v u l a P p a l. B a j0%External LeakMultiple possibilities for this defectMain Valve Leak S pecific M easurable A ction Oriented R ealisticT ime & Results ConstraintsClimate ControlsClimate ControlsClimate ControlsClimate ControlsClimate ControlsClimate ControlsClimate ControlsClimate ControlsClimate ControlsClimate ControlsClimate ControlsClimate ControlsClimate ControlsClimate ControlsContainers to return PlugsClimate ControlsOperators installing plugs after the parts are washed.Parts stacked in container ready for shipmentClimate Controls End Results PhotosSubsequent operations. No problems。