Final Exam: Summer 2020        MnH1

MGT 460: Six Sigma and Lean Manufacturing

Total points: 65
Student Name: Ajouwad Khandoker                                
Student ID:      1620001030
Instructions:
 Deadline: October 3, 2020, by 7 PM
 Late submission will not be accepted.
 Each answer should not be more than 2 pages. 
 You can also write mathematical answers in your copy, take a picture and then
paste it. You can also use excel if necessary. Please also upload the excel file.   
 Make sure your handwriting is legible; otherwise I will not mark it. 
 Please be specific while answering and try to use examples where relevant.
  Do not copy answers from others or directly from slides, books and the Internet.

Please write your answer in this Google doc.      

1. (15 Points) A project manager has set up an experiment to find out the effects of steel grade
and production temperature on the yield strength of material. Previously the temperature ranging
from 70 to 90 degrees Celsius and grade SS304 and grade SS316 has been used. He recorder the
following results

Run Steel grade Temperature Y

1 -1 -1 27,800

2 +1 -1 28,740

3 -1 +1 32,150

4 +1 +1 31,240
 
 a) Plot, quantify, and compare the main effects for each factor and also the interactional effect.
(Solve this math in excel and than paste the graphs below)
b) Determine which effects are significant
c) Create the specific Y = f (X) equation for this example
Answer to Question No 1:
A)
 Run Steel Temperature Y
grade
1 -1 -1 27,8
00
2 1 -1 28,7
40
3 -1 1 32,1
50
4 1 1 31,2
40

SS304 SS316
*E1=15 (Low) (High)
*E2=3425 29975 29990

90(Hig
70(Low) h)
Steel Grade Temperature 28270 31695

Run Steel grade Temperature C12 Y

1 -1 -1 1 27,800
2 1 -1 -1 28,740
3 -1 1 -1 32,150
4 1 1 1 31,240

*E12=-925

X1-X2 70(low) 90(High)

SS316(High) 28740 31240

 SS3049Low) 27800 32150

B)

Effect Value Rank (i) P Z

E12 -925 1 0.166 0.565921525
E1 15 2 0.5 0.691462461
E2 3425 3 0.833 0.797577635

Value Z
-925 0.565
15 0.691
3425 0.797

*The affect of E2 is significant

C)

Y = fx
Y= B0 + B2 X 2
29982.5 + 1712.5 X 2
2. (15 Points) An operation manager is trying to find out the relation between the quality of the
components manufactured in a machine and the hours of training the machine operator have had.
He observed the number of defects found out of 100 parts inspected for 18 machines and the
hours of training provided to each respective operator of those machines. The data is as follows
Training Defects (Per 100) Training (Hours) Defects (Per 100)
(Hours)

8 5 7.6 7

8.3 3 9.4 1

7.5 3 9.6 1

8.1 7 7.8 7

8.5 9 7.8 5

8.8 6 8.3 7

9.5 3 9.7 5

7.4 6 9.9 7

8.3 7 8.5 11
 
a) Is the hour of training of the operators and quality of the components correlated? Do you think
increasing training of the operators will improve the quality of the components?
b) Calculate the equation for the line fitting the training hours – part quality data. Plot the line on
a graph along with the original data.
c) Calculate the expected defects per 100 parts for operators with 8, 10 and 11 hours of training.
  (You may use excel to solve this math in excel and than paste the graphs below)

Answer to Question No 2:
A) Correlation shows the strength of the relationship between two variables. In this case, the
hour of training of the operators and quality of the components are weakly positively
correlated (Correlation : 0.29006).
So, I think increasing training of the operators will improve the quality of the components
but not significantly . If, the correlation> 0.5 then, it will show a strongly positive
relationship between two variables .But, In this case the relationship shows weakly
 positive relationship between the hour of training and quality of the components that
means these two variables are weakly positively correlated.
B)

X (Traing Y (Defects per

Hours) 100)
8 5
8.3 3
7.5 3
8.1 7
8.5 9
8.8 6
9.5 3
7.4 6
8.3 7
7.6 7
9.4 1
9.6 1
7.8 7
7.8 5
8.3 7
9.7 5
9.9 7
8.5 11

- (Weakly negetively
Correlation 0.29006 correlated)
C)

*The expected defects per 100 parts for operators with 8 hours of training = (8/100) = 0.08

*The expected defects per 100 parts for operators with 10 hours of training = (10/100) = 0.1

* The expected defects per 100 parts for operators with 11 hours of training = (11/100) = 0.11
3.  (10 Points) Suppose you are working in a manufacturing company’s Sales Department. Main
responsibility of your team is to receive the sales orders from the company’s website and process
the order. The order-processing function usually involves checking customer credit, sending the
order to the inventory and shipping areas, and preparing shipping documents. Part of the order
processing is done in a computer and the rest of it is manual, where you need to complete some
important paperwork. In the workplace there are 10 computers for each of the employees and
three common printers located in front of the room side by side. The physical items besides the
computers and printers include files, documents, brochures, letters, printer cartridge, white
papers, sticky notes, pens, notebooks, paper clips, stapler, and so on.
The workplace is not properly organized and it is difficult for the team members to find out
different things when necessary. At the same time, the workplace is cluttered with many
unnecessary items like old forms, documents, old brochures, faulty stationery etc. Due to the
current Covid situation, it is very important to practice social distancing while working. Your
manager has asked you to come up with a plan to make your workplace more organized, which
not only ensures the distance between the employees but also will increase the efficiency of the
workplace.
Which of the lean concepts you can use to come up with a plan? Explain the steps you will use.

Answer to Question No 3:
Eliminating waste is the only way to improve any situation. So, In order to increases the
efficiency, here I need to eliminate the process. Not all the waste can not be eliminated. I need to
follow some steps:

 First of all I need to focus on the current state

 I need to find out or identify the waste
 I will have to eliminate the waste and
 Finally, I will have to solve the problem.

In order to eliminate the waste in this case I will have to follow some steps and those are given
below –

> In the workplace there are 10 computers for each of the employees But there are only three
common printers for all. So here, we need 7 more printers .That means, if we have 10 printers for
10 people then the work speed will automatically increase as well as the lead time will also
decrease.
> In this case, The workplace is not properly organized .The physical items such as files,
documents, brochures, letters, printer cartridge, white papers, sticky notes, pens, notebooks,
paper clips, stapler etc. need to place at a specific place or at the right place, so that we could
find the items whenever we need those. These things are not so expensive, so in order to
increase the work flow we need each of the items individually.
> The workplace is cluttered with many unnecessary items like old forms, documents, old
brochures, faulty stationery etc. So in order to organize the workplace we need to takeout the
unnecessary items from the workplace. It will increase the work speed as well as the
environment of the workplace would be changed.
These steps are helpful for eliminating the waste as well as for improving the efficiency. These
steps will also help us to keep social distance in this pandemic COVID situation. If all the
elements are near to us then it will help us to keep social distance. On the other hand, each of the
employees will have to wear the mask as well as wash their hands frequently while working in
the work place.

If we use the lean concepts then we would be benefited by these factors -

 It will provide tangible benefits for the company.

 It will reduce the costs, So it will automatically reduce the selling price.

 It will reduce the delivery time, cycle time, set-up time. So, the work follow will increase.

 It will Eliminates the actual waste and it is positive sign of any company.

 It will help to continuously improve the overall process.

 IT will improve the quality.

 It will improve the customer ratings and perceptions & it would be beneficial for all the
manufacturer company to make loyal customers.

 It will Increase overall customer satisfaction

 It will also improve employee involvement, morale, and company culture as well.

4. (10 Points)  Identify which activities come under which 7 waste of Lean Manufacturing?
Explain briefly.    
a) Pearl ltd is a small-customized printing company specializes in invitation cards. When a client
comes to choose a design for cards, an employee of the company first lists down all the
specifications of the customer and creates a sample card by using a computer. A specialized
printer is used to print out the card for the customer’s approval. The printer is located in a
separate area, which resulted in employees having to walk to the printer and bring it back to the
customer every time. As a result, the service time for one client increases and many times the
clients have to wait in a queue to get served.
b) A manufacturing company sources raw materials from five different vendors. Most of the time
due to lack of coordination, the company experiences delays, while receiving all the raw
materials required for production. As a result many times the company cannot uphold their
production schedule. 
c) CEO of company X is known for her strict supervision and quality control. Although the
company has successfully achieved the specification of the customer requirement and provided
the customers higher quality goods, the CEO is pushing the R&D to make more changes to the
current design, which is not going to benefit the customer anymore.
Answer to Question No 4:
A) These activities come under the Transport waste of Lean Manufacturing. Here, the
unnecessary movement of materials such as work-in-progress (WIP) materials being transported
from one operation to another. Usually, it adds time to the process during which no value-added
activity is being performed.

In this case, the printer is located in a separate area, which resulted in employees having to walk
to the printer and bring it back to the customer every time. As a result, the service time for one
client increases and many times the clients have to wait in a queue to get served. So, this
activities falls under transportation waste of lean manufacturing.

B) These activities come under the Waiting waste of Lean Manufacturing. Whenever a person, a
part, a material, information, or equipment sits idle without something being done to it, it falls
under waiting. It is also known as queuing. Here, Periods of inactivity in a downstream process
that occur because an upstream activity does not deliver on time.

In this case, the company experiences delays, while receiving all the raw materials required for
production. As a result many times the company cannot uphold their production schedule. So,
This is falls under the waiting waste of Lean Manufacturing.

C)This activities comes under the Extra processing waste of Lean Manufacturing. When you
perform more work on an item than I needed, you’re creating extra processing, which is a kind of
waste. Usually, this term refers to extra operations, such as rework, reprocessing, handling, and
storage, that occur because of defects, overproduction, and too much or too little inventory. It is
more efficient to complete a process correctly the first time instead of making time to do it over
again to correct errors.

In this case, the CEO is pushing the R&D to make more changes to the current design, which is
not going to benefit the customer anymore. This is falls under the extra processing waste of Lean
Manufacturing.
5. (15 Points) X Company produces coat hangers for Garments Company. This case concerns
one product family, a wire hanger, which has a simple loop of wire, most often steel, in a
flattened triangle shape that continues into a hook at the top. These components sent to Y Ltd
Company (The customer)
Production Process
 X’s processes for this product involve cutting a metal part followed by blending,
braiding, and subsequent packing. The components are then shipped to the garment’s
warehouse, which takes two days. 
 Steel coils are supplied by Z Steel Co. Steel deliveries to X, with delivery time of 2 days
using trucks
Customer Requirements
 100,00 pieces per month
 Customer plant operates on three shifts,
 One shipment every day to the warehouse by truck.
Production Control Department
 Receives Y’s monthly forecasts and enters them to MRP. (Electronically)
 X issues a 3-week forecast to Z Steel Co. via MRP. (Electronically)
 Secures steel by weekly Mailed order release to Z Steel Co. (electronically)
 Receives bi-weekly order from Y Garments. (Electronically)
 Issues weekly build schedules to Cutting, Blending, Braiding, and Packing processes.
Process Information
All processes occur in the following order and each piece goes through all processes. All the
WIPs are pushed to the succeeding departments.
1. Cutting
 Cycle Time: 2 second
 Changeover time: 5 min (good piece to good piece)
 Automatic process with 1 operator
 Observed inventory:
o 2 days of coils before cutting
o 1000 Pieces

2. Blending
 Automatic process with two operator
 Cycle Time: 10 seconds
 Changeover time: 10 minutes (fixture change)
 Observed inventory: 
o 3 days before blending
o  6000 pieces

 
3. Braiding
 Automatic process with five operator
  Cycle Time: 10 seconds
 Changeover time: 5minutes (fixture change)
 Observed inventory:
o 5 days before braiding
o 16000 pieces

4. Packing
 Manual process with five operator
 Cycle Time: 2 min
 Changeover time: 5 min
 Observed inventory:
o 2 days before packing
o 4 days after packing
o 1,200 pieces

5. Shipping Department
 Removes parts from finished goods warehouse and stages them for truck shipment to
customer
a) Draw the Value Stream Map for the above process.
b) Calculate the total production time and total value added time.

Answer to Question No 5:
A)

Value Stream Map

B) Total production time =(2+3+5+2) days

= 12 days

Total value added time =2+10+10+(2*60) seconds

= 142 seconds