DMAIC

Project Name : Cycle time reduction.

Project Owner : s.n. parmar,ajay kumar
choudhari

03/01/16

Overview

Project Progress Overview

Define

Measure

Analyze

18may/2013

18/d05/2013

27/05/2013

05/06/2013

15/March/2010

mm/dd/yyyy

mm/dd/yyyy

mm/dd/yyyy

Tollgates:
Planned
Completed

Steps:

03/may/2013

XXXXXX

D1. Map Project

D2. Approve Project

M1. CTQ Characteristics&

Standards
M2. Measurement System
Analysis
M3. Data Collection

A1. Baseline Process

A2. Performance
Objective
A3. Identify Drivers of
Variation

Improve

I1. Screen for Vital Xs

I2. Screen for vital Xs
I3. Define Improved
Process

Control

C1. MSA on Xs
C2. Improved Process Capability
C3. Establish Control Plan

Key Deliverables:
List of Customer(s) and
Project CTQs
Team Charter
High Level Process Map
(COPIS)
CAP Plan (Optional)
Preliminary CBA, if
applicable

Tools:

Survey
Focus Groups
Interviews
ARMI, Stakeholder
Analysis
In/Out of Frame
Threat vs. Opportunity
Matrix
Other ______________

QFD / CTQ Tree

Operational definition,
Specification limits,
target, defect definition
for Project Y(s)
Data Collection Plan
Measurement System
Analysis

Data Collection Plan

Continuous Gage R&R
Attribute Gage R&R
Sample Size Calculator
Other ______________

Baseline of Current
Process Performance
Normality Test
Statistical Goal
Statement for Project
List of Statistically
Significant Xs

List of Vital Few Xs

Transfer Function(s)
Optimal Settings for
Xs
Confirmation
Runs/Results
Tolerances on Vital
Few Xs

Basic Statistics
Histogram
Dot Plots
Box and Whisker Plots
Run Charts
Normality Testing
Continuous/Discrete Zst, Zlt
Benchmarking
Detailed Process Mapping
Moments of Truth
Nature of Work
Flow of Work
Fishbone
Hypothesis Testing
Regression Analysis
Other ______________

DOE
Pugh Matrix
New Process Mapping
FMEA on new process
Process Modeling /
Simulation
Other ______________

MSA Results on Xs
Post Improvement
Capability
Statistical Confirmation
of Improvements
Process Control Plan
Process Owner Signoff
Final CBA, if applicable

Continuous Gauge R&R

Discrete Gauge R&R
Control Charts
Hypothesis Testing
CAP Plan
Control Plan
Other ______________

03/01/16

Define

1.
2.
3.
4.
5.
6.

Blank
Project Charter
Terms and Acronyms Used
ARMI & Communication Plan/Why not RASIC
SIPOC
Process Map

03/01/16

Define

Customer
Maheh kumar
(CEO)

Sample Comments
we are facing our CD manufacturing cycle time

Key Output Characteristics

Important to Customer (CTQ's)
Reduce cycle time .

is very high 405 second Instead of 300 second

ABC Ltd.

so we are not achieving Production on time.

Ajay Kumar choudhari

Customer not received product on time .

Reduce cycle time.

General manager
ABC Ltd.

Customer

03/01/16

Project Charter
Business Case:ABC Ltd. is the largest optical
media manufacturer in the world. We are also
manufacturer photo voltaic cell. We make CD
/DVD at automation line from raw material
(polycarbonate) to final disc in which use of
polycarbonate, dye, ml, bonding glue ,silver etc.
First time raw material (polycarbonate ) feeding
in moulding m/c after we receive blank substrate
disc than disc going for dye coating than coated
disc go to dryer for 30 minutes at 90 degree
farnhite temp. after than silver coating on the
disc for reflectivity . And take one blank
substrate disc bonding on dye coated disc.
Problem Statement: Last two months data show
that average cycle time 405 second instead of
300 second which is 53% productivity loss from
our target and its effect on our customer and
profit. .
Goal Statement: I will be reduc the cycle time 405
to 300 second on dated 15 th june 2013.

Define

In Scope:Quality control.

Out of Scope:All the other process of this

organization.
.

High Level Project Plan

Milesto
ne

Target Date

Start
Date

Actual Date
Xxxx

03/05/2013

10/05/2013

18/05/2013

27/05/2013

05/06/2013

03/01/16

Terms and Acronyms Used

Define

Definitions:
Indicators

Definition

03/01/16

ARMI & Communication Plan

Define

ARMI Worksheet
Key
Stakeholders

Define

Measure

Analyze

Improve

Control

Stakeholders-CEO

Sponsor-VP

Hod of production

Quality head

BB

M/A

Team Members

Communication Plan
Message

Audience

Media

Who

When

Project Status

Leadership

E Mail

BB

Weekily

Tollgate Review

VP,BB,HOD PROD.,HOD
QUALITY,

E mail conference calls

meetings

BB

As per project plan

MEMBERS

E mail conference calls

meetings

BB/MEMBER

WEEKILY

Project Deliverables or
Activities

When Populating the Stakeholder, consider the ARMI:

A=
Approver of team decisions
R=
Resource or subject matter expert (ad hoc)
M=
Member of team
I=
Interested Party who will need to be kept
informed

03/01/16

SIPOC
SUPPLIER

Define

INPUT

PROCESS

OUTPUT

CUSTOMER

ABC Ltd.

Werehouse

Raw material
(PC)

production

production

ABC Ltd.

Moulding
machine

Moulding (make
blank substract)

production

production

ABC Ltd.

Dye lab

Dye coating on
blank substract

production

production

ABC Ltd.

Disc dryer

Dry the disc in

the dryer

production

production

ABC Ltd.

sputter

Silver coating on
the disc

production

production

ABC Ltd.

Store/bonding
material

One substract
disc bond on the
dye coated disc.

production

production

ABC Ltd.

scanner

Final scanning.
At scanner

production

production

ABC Ltd.

production

Finished disc

production

Quality

03/01/16

Measure

1.
2.
3.

Data Collection Plan

Measurement System Analysis
Process Capability

03/01/16

Data Collection Plan

Y

To reduce
cycle time.

Measure

Operational
Definition

Defect
Definition

Performance
Standard

Specificatio
n
Limit

Opportunity

Disc cycle
time should
not be more
than 300
seconds.

More then 300

c/s per disc.

300 sec.

Usl (300 sec.)

weekly

Mode of collecting Data

Data
Base
Containe
r

Existing
or new
data
base
Two month
old data

Data Type

Unit

Decimal
to be
Used

To reduce
cycle time

continuous

seconds

Excel
Equipme
nt
Calibratio
n
Informati
on

Formul
a to be
used

Data
items
needed

Equipme
nt Used
for
measure
ment

Total
production /
total time.

Cycle time

Timer
clock

weekly

If New
when
data
base
would be
ready.

Plan
start
date for
DCP

yes

03/05/13

Responsi
bility

Any
Training
need

Operator
Informati
on

BB

yes
Mr.
mahant
10

03/01/16

Measurement System Analysis

Measure

Minitab Descriptive Stats

Gage R&R
%Contribution
Source
VarComp (of VarComp)
Total Gage R&R
0.2
0.00
Repeatability
0.2
0.00
Reproducibility
0.0
0.00
oper
0.0
0.00
Part-To-Part
25932.1
100.00
Total Variation 25932.3
100.00

Rule

R&R % of
Tolerance

% Contribution
(R&R Std
deviation)

Number of
distinct
categories

Process tolerance = 1
StudyVar
%StudyVar %Tolerance
Source
StdDev (SD) (6*SD)
(%SV) (SV/Toler)
Total Gage R&R
0.410
2.458
0.25
245.79
Repeatability
0.410
2.458
0.25
245.79
Reproducibility
0.000
0.000
0.00
0.00
oper
0.000
0.000
0.00
0.00
Part-To-Part
161.035 966.208
100.00 96620.76
Total Variation
161.035 966.211

Rule
Description

Acceptable

Result

0.25%

ok

ok

554

ok

Overall Gage result

Ok

11

03/01/16

Measurement System Analysis

Measure

12

03/01/16

Process Capability

Measure

since P value
<0.05 hence
it significant
effect on
population.

Data is not normal so that the process

Capability is not require so DPMO calculate.
13

03/01/16

Measure

DPMO

Dpmo = defect per oportunity * 1000000

=0.5349264*1000000
= 5349264
Dpo = total no of defect /total opportunity
= 291/544 = 0.5349264

Sigma level =1.40

14

03/01/16

Analyse

1.
2.
3.
4.
5.
6.
7.

DCP for Potential Xs

Identify Potential Xs
DCP for Potential Xs
Basic Analysis for Project Y
Checking for Impact of ...... on Y
Hypothesis Summary
MSA results of Impacting Factors

15

03/01/16

Identify Potential Xs

Analyse

Factors identified through brainstorming

16

03/01/16

Basic Analysis of Project Y

Analyse

Randomness & Shape Study

Normality Study

Since p -value is less than 0.05, hence the data is not normal.

17

03/01/16

Randomness Study

Analyse

18

03/01/16

Stability Study

Analyse

P value for
Trend is
less than
0.05 so it is
significant
impact on
my Average
cycle time.

The RUN chart shows that Trends exists in the data while there are no
mixture ,oscillation and Clustering . This evidently shows that the data
is not stable.
19

03/01/16

Basic data distrubution Analysis of Project Y

Spread Study

Analyse

Central Tendency
Study

Any data on
this side is
consider as a
defect

There is too much variation in the system.

20

03/01/16

Basic Analysis of Project Y

Analyse

Study Spread and Central Tendency

Spread Study

Range
Variance
Std deviation
IQR

=
=
=
=

990
74756.70
273.42
475.50

Central Tendency
Study

Mean
Median

= 405.65
= 336.00

21

03/01/16

e
Th enc Analyse
qu s
e
fr y i te
i a he
v
de m t so
.
fro get n
r
ta ea te
m ia
v
r
de hge
hi de.
si

22

03/01/16

Checking for Impact of on Y

Analyse

The box plot shows that more then 75% population is below the target
of 95%.
23

03/01/16

Analyse

Leven test

24

03/01/16

Hypothesis Summary

Analyse

Summary of Impacting Factors

Sl.
No.

Factor

P
Value

Graphical Tool Inferenc

Used
e

Age

0.703

Correlations &
regration

Process knowledge

0.847

Correlations &
regration

Age

0.762

no

Team Leader

0.007

yes

trainer

0.121

no

shift

0.922

no

gender

0.762

location

0.042

Education

0.429

Marital status

0.81

Mode of
communication

0.547

Average cycle time

0.1029

levene

Next
Steps

no
no

no
yes
no
no
no

Sign Test for Median

No
25

03/01/16

Hypothesis Summary

Analyse

Summary of Impacting Factors

Sl.
No.

Factor

P
Value

Gender

0.8749

No

Education

0.8394

No

Process
Complexity
Location
Marital Status
Communication
Associate Name
Team Leader
Process
Complexity
Trainer
Shift

Graphical
Tool Used

0.5179
0.6688

Mann-Whitney Test

0.521
0.000
0.033

No
No

0.8065

0.508

Next
Steps

No

0.9813

0.936

Inferenc
e

No
Mood Median Test

No

Mood Median Test

No

Mood Median Test

No

Mood Median Test

Mood Median Test

yes
Yes

26

03/01/16

Vital Xs that are impacting the

AvERAGE CYCLE TIME

Analyse

27

03/01/16

MSA Results of Impacting Factors

Analyse

Checking the Validity of the data of the impacting factors

Sl.
No.

Factor

MSA
Method
Used

Result

RCA for
Problems

Next
Steps

28

03/01/16

Improve
1.

Screening of the Impacting Factors

2.

Action Plan for Improving the Factors

3.

Basic Analysis of Improved Y

4.

PrePost Analysis of Project Y

5.

Pre-Post Analysis of Factor

6.

Improve Summary Take Aways

29

03/01/16

Screening of the Impacting Factors

Improve

Prioritize the Impacting Factors

30

03/01/16

Action Plan for Improving the Factors

#

Pain Area

Root Cause

Improvement Idea

Implementatio
n
Owner

Improve

Implementatio
n Status

31

03/01/16

Basic Analysis of Improved Y

Improve

Randomness, Shape , Spread & Centering Study

Randomness Study

Spread Study

Normality Study

Central Tendency
Study

32

03/01/16

Pre-Post Analysis of Project Y

Improve

Statistical Validation of Impact

Graphical Depiction

Hypothesis Result

Inference :
33

03/01/16

Pre-Post Analysis of Project Y

Improve

Statistical Validation of Impact

Graphical Depiction

Hypothesis Result

Inference :
34

03/01/16

Pre-Post Analysis of Factor

Improve

Statistical Validation of Impact

Graphical Depiction

Hypothesis Result

Inference :
35

03/01/16

Pre-Post Analysis of Factor

Improve

Statistical Validation of Impact

Graphical Depiction

Hypothesis Result

Inference :
36

03/01/16

Pre-Post Analysis of Factor

Improve

Statistical Validation of Impact

Graphical Depiction

Hypothesis Result

Inference :
37

03/01/16

Pre-Post Analysis of Factor

Improve

Statistical Validation of Impact

Graphical Depiction

Hypothesis Result

Inference :
38

03/01/16

Improve Summary Take Aways

Improve

39

03/01/16

Control

1.
2.
3.
4.
5.
6.
7.
8.

Control Plan & FMEA on Control Plan

Time Series Study of Y Pre & Post
Control Charts & Inference for Y Pre & Post
Basic Analysis of Improved Y
Establish Process Capability
Control Charts & Inference (for X1)
Control Charts & Inference (for X2)
Cost Benefit Analysis and Sign Off

40

03/01/16

Control Plan & FMEA on Control Plan

Whats Controlled

Goal/Spec Limits

Control Method

Who/What
Measures

Control

Decision
Where
Rule /
SOP
Recorded Correctiv
e Action

41

03/01/16

Time Series Study of Y Pre & Post

Control

42

03/01/16

Control Charts & Inference For Y Pre & Post

Control

43

03/01/16

Basic Analysis of Improved Y

Control

Randomness, Shape , Spread & Centering Study

Randomness Study

Spread Study

Normality Study

Central Tendency
Study

44

03/01/16

Establish Process Capability

Control

Process Capability Post Implementation

Z Bench
(Long Term Sigma)

Short Term Sigma

(Long Term Sigma +1.5)

45

03/01/16

Control Charts & Inference (For X1)

Control

46

03/01/16

Control Charts & Inference (For X2)

Control

47

03/01/16

Cost Benefit Analysis & Sign Off

Benefit
Source

Unit Benefit Units

Impacted

Control

Total
Benefit

Cost Reduction
Enhanced Revenues
Labor Reduction
Decreased Overhead
COPQ Cost Reduction

48

03/01/16

49

03/01/16

Terms & Definitions Used

Indicators

Definition

50

03/01/16