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Demonstrating Customer Value

Six Sigma in Action:

Master Black Belt: Steven Bonacorsi

Six Sigma in Action:


Customer Profile GE Aircraft Engines, Evandale, OH Business Problem & Impact
The data conversion process within the install process can take up to 5 or 6 hours to complete, requiring extra resources for refresh and installs.
Proc es s Data

Data Conversion Cycle Time


Process Capability Before
P ro c e s s C ap ab ility A nalys is fo r T o tal T im e
USL
* * 90.740 30 64.1700 75.7250

Measure & Analyze

USL Target LSL Mean

120.000

ST LT

Data Collection: Cycle times were measured (average was 90


minutes), then segmented by time of day, type and size of files, etc. to identify and isolate root causes. Root Causes: File sizes, network traffic, and obsolete compression processes were determined to be the major causes of process defects
StDev (ST) StDev (LT) Cp CPU CPL Cpk Cpm Sample N

Potential (ST) Capability * 0.15 * 0.15 *

Improve & Control

-100
PPM < LSL PPM > USL PPM Total

0
*

100
PPM < LSL PPM Total

200
*

300
PPM < LSL PPM > USL PPM Total

400
* 0.00 0.00

Network issues were completely eliminated by utilizing direct PC connection to a mobile laptop and network crossover cables during setup. The ITS project leader developed the QuickBack 32 application to Process Data USL 120.000 address data compression issues.
Pp PPU PPL Ppk

Ov erall (LT) Capability * 0.13 * 0.13

Obs erv ed Perf ormanc e 266666.67 266666.67

Ex pec ted ST Perf ormanc e PPM > USL 0.00 0.00

Ex pec ted LT Perf ormanc e

Process Capability After

Process Capability Analysis Total Time

USL
ST LT

Results/Benefits

T arget LSL Mean

* * 10.825

Drastically improved cycle time, decreasing it from an average of 90 to 30 Sample N StDev (ST ) 10 minutes. Span (longest cycle time) was reduced from 291 to 33 8.15756 StDev (LT ) 8.66795 minutes. which lead to dramatic productivity savings for GEAE and ITS. Potential (ST ) Capability Because one less technician was required for the PC install Cp process, the * CPU 4.46 client achieved a productivity savings of over $83,000 annually, in CPL * Cpk addition to the cost avoidance of over $90,000 from not having to hire 4.46 Cpm * additional personnel and an extra delivery van as originally scheduled. Also, end users were more satisfied with the overall install process. Overall (LT ) Capability
Pp PPU PPL Ppk * 4.20 * 4.20

0
PPM < LSL PPM > USL PPM T otal

20
* 0.00 0.00

40
PPM < LSL PPM > USL PPM T otal

60

80
* 0.00 0.00

100
PPM < LSL PPM > USL PPM T otal

120
* 0.00 0.00

Observed Performance

Expected ST Performance

Expected LT Performance

Increased clients staffing productivity by $83K while improving performance!