Current Delivery Volume/Week

Sealant Type 1oz 3oz 6oz Total Count Total Ounces

1995C 50 50 300
2082 B2 40 160 200 520
870 C6 24 24 144
870 GRV 50 50 300
AC730 B2 50 30 80 330
5896-2 B1/2 440 100 540 1,920
5896-2 B2 620 100 720 2,460
5896-6 400 900 250 1550 4,600
Total Count 440 2,170 604 3,214
Total Ounces 440 6,510 3,624 10,574
 Expired Ounces Scrapped
Sealant Type
Ounces/Week After Use/Week Average Total Ounces
Wasted/Week
1995C 140 35 175
2082 B2 201 120 321
870 C6 - 40 40
870 GRV 122 10 132
AC730 B2 32 44 76
5896-2 B1/2 776 324 1,100
5896-2 B2 1,641 375 2,016
5896-6 260 1,061 1,321
Total 3,172 2,009 5,181
 Sealant delivered to Quality Department
Assembly Transportation inspects sealant
Supervisor has Department warehouse
weekly and inspected
standing order
tment PCU transport sealant to PCU distributes sealant to
nt assmebly areas and loads POU freezers
Pass main freezer
inspection?

No

Quality Department
scraps batch
Mechanic searches
freezer for sealant Mechanic
Sealant thaws, applies,
Available? and dispose
excess

No

Mechanic informs
supervisor to order or
restock

Supervisor
expedites order
and/or updates
standing weekly
order
 1oz 3oz 6oz Sealant Type Ounces Ordered %
order volume 440 6510 3624 5896-6 4,600 44%
5896-2 B2 2,460 23%
5896-2 B1/2 1,920 18%
Order Volume by Tube Size 2082 B2 520 5%
1oz 3oz 6oz AC730 B2 330 3%
1995C 300 3%
4%
870 GRV 300 3%
870 C6 144 1%
34%

Sealant Type Ordered Paret

5,000
62%
4,500
4,000
3,500
3,000
2,500
2,000
1,500
1,000
500
-
6 B2 /2 B2 B2 5C
9 6- 2 B1 2 0 9 GR
58 6- 2 08 73 19 0
89 9 6- 2 A C 87
5
58

Ounces Ordered Cum %

 Average Total
Sealant Type Ounces
Cum % Wasted/Week % Cum %
44% 5896-2 B2 2,016 39% 39%
67% 5896-6 1,321 25% 64%
85% 5896-2 B1/2 1,100 21% 86%
90% 2082 B2 321 6% 92%
93% 1995C 175 3% 95%
96% 870 GRV 132 3% 98%
99% AC730 B2 76 1% 99%
100% 870 C6 40 1% 100%

Type Ordered Pareto Sealant Type Wasted Pareto

120% 2,500
100%
2,000
80%
1,500
60%
1,000
40%
500
20%

0% -

B2 B2 C V C6 B2 -6 /2 B2 5C V B2
5 GR 2 6 B1 2 9 GR 0 0
82 30 1 99 0 70 6- 5 89 - 2 08 19 70 73 87
20 AC
7 87 8
5 89 96 2 8 A C
58

Ounces Ordered Cum % Average Total Ounces Wasted/Week Cum %

asted Pareto
120%
100%
80%
60%
40%
20%
0%
5C GR
V B2 C6
0 0
87
0 73 87
AC

ted/Week Cum %
 Average Total Average Total
Sealant Type Ounces Ounces
Wasted/Week Wasted/Week DPO DPMO Sigma Level
1995C 300 175 0.583333 583,333 1.29
2082 B2 520 321 0.617308 617,308 1.20
870 C6 144 40 0.277778 277,778 2.09
870 GRV 300 132 0.44 440,000 1.65
AC730 B2 330 76 0.230303 230,303 2.24
5896-2 B1/2 1,920 1,100 0.572917 572,917 1.32
5896-2 B2 2,460 2,016 0.819512 819,512 0.59
5896-6 4,600 1,321 0.287174 287,174 2.06
Total 10,574 5,181 0.489975 489,975 1.53
Failure Mode
Causes RPN

No one is
monitoring the
consumption data 125

Lack of sealant
focal point 125
Lack of defined
business process 125
Distributor lacks
accurate
information 100

Inaccurate
consumption data 75

Distributor is
delayed by other
work 75
Mechanics taking
too much sealant 50

Power outage 15
 Recommendations
Define a focal point, monitor
and document consumption
rates
Define a focal point, monitor
and document consumption
rates
Process flow charted by
Green Belt Team

Each freezer needs a sealant

requirements list

Define a focal point, monitor

and document consumption
rates for sealant types and
tube sizes

Establish a sealant
distribution person to deliver
sealant on a specific day and
time for each unit
Check out sheet to monitor
sealant consumption

An external temperature
recorder and alarm/light
indicator when/if temperature
falls below spec