Day 4

_____

Define
MEASURe

1) Data collection

2) Normal---

Hypothesis Testing----

Parametric
No--------
1) Increase the sample size
2) Remove/ treat the outlier--------- Box
Plot.. Run.. Control
3) Data Transformation--------------------
4) Non Paramteric Tets

Process baselining
Sigma level computation

DPMO------------------------- Defect per Million

opportunities------------------ Discrete
Process capbility analysis---- CP and
CPK-------------------------------------- Continuous

DPMO----
Defect---------------------- NC to Specification limit
Defect Opportunity--- maximum defects possible in 1 product
Defective------------- Any part.. having some defects

100 Pens

4 Defect are possible in each pen

200 defects--- Cost of REWORK------ COST OF APPRAISAL-----COST of PRevention

DPMO-- not majorly used.. Prone to biasness.. manupulated

ONLY---- sigma lveel00 discrete

1 Chair

Defect opportunities in the chair

- finishing not good
- Dimentional stability
- cushioning
- Arm rest/ back rest
- Wheel rotation
- Ht of the chair
- Minor Cracks
- Cost
- transportation of the / packaging
3

10 Defect Opportunities
N= 100 Chairs

Defect = 200
_____________________________ 0.005 *1M= 50000--- Adbrided
table----3.4 DPMO
Maximum defect = 100000

1M

COKE CKOE
Each alphabet-- DO------- Increasing the DO---

DO---- Customers

Defects-----

Process Capability analysi----- CP and CPk------- Accurate sigma--- Cont.

Kurtosis--- Cp
Skewness----- Cpk

CP = Kurtosis= Variation

1) Total Variation= Measrument variation + {rpcess variation

Process Variation = Centricity + Variation

Cpk Cp

CP = (USL-LSL) / 6*s--

CPk (USL-X)/ (3*s)---- CPU

(X-LSL) /(3*s)----- CPl

CPk== min (CPl, CPu)

- CP value is negative
CPK value is < 0
- CP value less than CPK

____________________________________________ MEAusre ____

ANALYZE-- List of causes and validating them

______

1) LEan Methodology
1) Process mapping
Operation----- Task----- Activity
SIPOC ------- SOP-------- Functional Deployment
charts

Waste elimination
Non value adding activities----

AS IS
DO not refer any Documents

2) Work Value Analaysis

VA
 NVA

I interviewed 10 resources
1 hour---- 10 hours

1 hire

Finance team-- 6 people--- 10 LPA

Transportation

VA
Is my customer Paying me for doing this or not?---

YES-------------- VA
NO-----
Can i eliminate it?
YES------------------ NVA
NO------------------- VE
/ENVA /BVA

Support function----- Enabling functions

Quality-------

VA--- synchornise
NVA---Eliminate
VE----Optimise

Maggi preparation

lEVEL-1 oPERATION
lEVEL 2 tASK
lEVEL 3 aCTIVITY
1) Boil Water
- Take tumbler
-Add water
- Walk 10 steps towards the tap--- ELIMINATED
- Extend my arm
- turn it clockwise-----
- Wait for it to fill 150 ml
- Turn it anti closkcwise
- Walk 10 steps towards the stove----- ELIMINATED
- Turn the gas on
- Wait for it to boil

wORKDAY

i NEED TO TAKE LEAVE

mY MANAGER-- 5 sEC

NOTIFICATION------

Team loading 70%

Va-----20%--------- synchronise
VE------ 60%------ optimise
NVA------- 20%--- eliminate

3) Cycle Time analysis------------ CTQ is time related

Lead Time------ Order to delivery

Takt Time--------Maximum time available for delivering 1
pizza------ Not Measure--- Calculated
Cycle time---- Actual time taken to
 9:00 ---- i picked up the phone
9:05----- i placed the order
9:10------ kitchen
9:15------ RM
9:20------ Oven in
9:40------ oven out
9:45------ Packaging
9:50------ Left
9:55----- i received it

8 hours shift TAKT TIMe8 (Breaks)= 420 mins (Available

time) 4.2 TAKT 3 mins
____
100 Cars

Available time (600) =60 Mins

______________
Customer emand (10)

Value Stream Mapping

(SIPOC + WVA + CTA + Information flow)

Last activity

VSM-- 1 st activity

WVA
CTA
Lean Methodology

Waste elimination

Transportation------ Excessive transportation----------------

Inventory------------ Excessive
inventory------------------------------------------------------- RM +
WIP-------------------- Capcity utilisation
Motion------------------------------------------------ 1.6 meters
Waiting------------ Waste
Overproduction---------------------------------------------------------------------
--- FG-----------------------------------
Over processing-----------------------------------
Defetcs---------------------------------
Skillset underutilisation----------

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