BADAVE ROOFING

COMPANY

(SIX SIGMA AND DMAIC APPROACH)

INTRODUCTION:

 Indigenous Ghanaian business with several years experience in the roofing industry.
The production process at BADAVE has been arranged as best as possible to meet
customer demand and achieve daily targets, such as in the production process for roof
panel.

CORE MANDATE:
 To Manufacture, design, sell, and install trusses as well as long span Aluminium and
Aluzinc roofing sheets.

BRANCHES:
 Kumasi, Accra, Takoradi, Tamale, Sunyani.
VISION :
To be a household name in the roofing infrastructure solutions industry in
Ghana and beyond

MISSION:
To provide quality and affordable roofing infrastructure solutions to Ghana
and the west Africa sub region.
CORE VALUES:
To work to ensure all our stakeholders benefit from our association.
To use quality materials backed by excellent installation and customer service.
To deliver on our promise.

GOAL:
To be a one - stop destination and a household name in the Roofing sector in Ghana and
beyond.

OBJECTIVES:
To increase our market share to about 75% of the total market in 10 years.
To improve our profit margin by 50% in 8 years.
To reduce defects in the production of roof by 80% in 2 years
METHODOLOGY:

The Six Sigma and DMAIC was deployed for the reduction of
defects in roofing quality.
DEFINE:

This phase clearly defines the team’s role, project scope and boundary as well as
customer requirements and expectations. . At this phase, the activities are selecting
and determining projects, determining problems and objectives, and making a
SIPOC (Supplier-Input-Process-Output-Customer) diagram. The determination of
the problem in this phase aims to improve the quality of specific processes.
HOUSE OF QUALITY:
It is a tool that shows how customer requirements relates to the technical specification companies can
use to achieve these requirements.

REASON FOR CONDUCTING SURVEY:

There has been a decline in the sales of the company. Therefore, it necessitated the conduction of this survey .

CUSTOMER REQUIREMENTS:
Interviews were used to generate the various requirements of customers.

TECHNICAL SPECIFICATIONS:
These are existing quality process details used by company to meet the expectations of customers .
NB: It is identified that
Galvanization is the highest
relative importance .
Therefore the lack of it leads
to Corrosion
CRITICAL TO QUALITY:
They are measurable characteristics of a process or service who’s performance specifications limits must be met in order
to satisfy the customer

PERFORMANCE
NEED DRIVERS REQUIREMENT

COLOUR COATING
QUALITY PAINT
QUALITY MATERIALS

ANTI - FADING
SATISFACTION
CUSTOMER

ANTI-RUST COATING
ANTI - RUSTING ADEQUATE ANTI-RUST VOLUME
STANDARDIZED ANTI-RUST APPLICATION

LOW MAINTENANCE
COST
WARRANTY GUARANTEED
QUALITY MATERIALS
TEAM COMPOSITION:
A five member team was put together to execute the project. Which includes :

 General Manager :
Responsible for the setting the annual goals, objectives as well provision of resources for
the project
 Project Manager:
Responsible for providing leadership, planning, supervise and directing of the entire
project.
 Factory Manager:
Responsible for ensuring that machines and equipment as well as other resources are in
their right conditions.
 Experienced Operator:
Responsible for operating the machines and other equipments

 Operations Manager:
Responsible for ensuring the availability of materials for the projects
PROJECT OBJECTIVES:

To improve our Galvanization process to eliminate the problem of

Rusting and Fading by 95% in 6 months.
SCOPE STATEMENT:
 Introduction:
As a team concerned with total customer satisfaction, our current customer rating against
our competitors in relation to poor anti–rusting properties of our products has necessitated
the need to improve the galvanization process to enhance customer satisfaction.

 Technical Details:
Thickness 0.475mm – 0.6m
Measurement 3.5 feet x 10/12/14/16
Flexibility Gauges are used to determine the flexibility
Galvanization Coating of Zinc over iron sheets Z40 – Z600
Colour Coatings Coated in colours that suits customer specifications
TIMELINE AND MILESTONES:

 Completion Period - Within 6 months

 Training Of Team Members - 2 Weeks
 Execution and Monitoring - 4 months
 Evaluation - 1 month
 Control - 2 Weeks
 Handing Over
 SIPOC (PROCESS MAPPING)

SUPPLIERS INPUTS PROCESS OUTPUTS CUSTOMERS

Shanghai Metal Corporation Galvanized Iron Coil Rolling Indented Box Rip Commercial
PPGI Manufacturer Cutting Indented Deep Proof Residential

Profiling Standard
Strip Lock
MEASURE:
There is currently a Sigma level of 1 and would like to move to Sigma 3
DPU = Defect DPMO = DPU * 1000000
Activities Number of Opportunity

= 45 DPMO = 0.045 * 1000000

1000 1
= 0.045 = 45000

Sigma (σ) Level Yield (%) DPMO

1 30.9 690,000
2 69.2 308,000
3 99.3 66,800
4 99.4 6,210
5 99.98 320
6 99.9997 3.4
ANALYSE:
PARETO CHART:

Cumulative
Problems Frequency Percentage
Percentage

Training problems 7 30% 30%

Operational defects 4 17.40% 47.40%

Material defects 3 13% 60.40%

Payment defects 3 13% 73.4

Machine Issues 3 13% 86.4

Supplier Issues 2 9.00% 95.4

Coating defects 1 4.30% 100

PARETO CHART: The root cause is the Training Issues

Chart Title
8 12000%

7
10000%

8000%
5

4 6000%

3
4000%

2000%
1

0 0%
Training problems Operational defects Material defects Payment defects Machine Issues Supplier Issues Coating defects

Frequency Percentage Cumulative Percentage

IMPROVE:

Brainstorming was done in order to arrive at these measures

 Use of Galvanized metal

 Regular Maintenance
 Application of Protective Coating
 Usage of stainless steel
 Keeping clean and dry surface
 Prevent scratches
CONTROL:
These measures were put in place to ensure to sustain the improvement measures

 Standardization
 Documentation
 Monitoring
 Training
 Response Plan
 Review and Sign - Off