Six sigma Black Belt project

Organization Name Place the team

Plant Location photograph here

Name of BB
Team Members

Project Sponsor
 Project planning
Month Month Month
Phase
W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4
Define

Measure &
Analyze

Improve

Control

Phases Planned Start Planned Actual start Actual Status

date Completion date completion
date date
Define

Measure &
Analyze
Improve

Control
 D
Define
DEFINE
M&A
Measure &
MEASURE & ANALYSE
Analyse

I
Improve
IMPROVE

C
Control
CONTROL
 D
Define DEFINE
M&A 1. Understanding the Problem
Measure &
Analyse

I
Improve

C
Control
 Phase – 1- Problem Definition (Understanding the
problem)
• Problem Statement
–
• Part number selected for study
–
• Other similar part numbers having the problem
–
• Other similar part numbers not having the problem
-
• Last manufacturing process stage where the Problem is generated
–
• Process stages where the problem is inspected currently
-
-
-
• Current average rejection in % for last 6 months
–
 Phase – 1- Problem Definition (Understanding the
problem)
• Maximum and Minimum rejection in % for the last 6 months
Month Rejection %
Maximum rejection
Minimum rejection

• Suspected physical phenomenon's that can lead to the problem

•
•
•
•
•
 Phase – 1- Problem Definition (Understanding the
problem)
• Actual physical phenomenon observed in the shop that is leading to the problem
-
-
-
-

• Date and shift in which the process was observed to identify the actual physical
phenomenon's:
•

• Tools/Techniques used for identifying the physical phenomenon

-
-
-
• Conclusions based on the Concentration chart done on the product
•
•
•
 Phase – 1- Problem Definition (Understanding the
problem)
• Number of lines/presses/machines used in the suspected last manufacturing
stage creating the problem
–
• Number of moulds in each equipment/machine
•
• Objective of the project
– To reduce the rejection from % to %

• Annual Savings in Rs. Lakhs if the defect is made zero in the part number
selected for doing the study
–
• Response
– Variable / Attribute

• Specification (if the response is variable)

–
Phase – 1- Problem Definition (Understanding the
problem)
Process Mapping clearly indicating the generating stage and inspection stages
Phase – 1- Problem Definition (Understanding the
problem)
Photograph of defect part
 Phase – 1- Problem Definition (Understanding the
Qty produced: 27651 nos.
problem)
Qty scrap – 540 nos.
Scrap % - 1.74
Blow hole scrap – 172nos.
Blow hole scrap % - 0.62
Defect selection Pareto (Based on last 6 months data)
Defectwise pareto analysis for Product XXX - Jul - Jan
99% 100% 100%
100%
500
82% 90%
80%
400
60% 70%

Contribution in %
Scrap in nos.

60%
300
32% 50%
200 172 40%
148
118 30%
90 20%
100
10%
2 1
0 0%
Blow holes Nonfilling Mixup Surface Setup scrap Crack
damages
32% of the rejection
Defect is due to Blow holes.

Double click on the graph to update the graph for your project
 Phase – 1- Problem Definition (Understanding the
problem)

COPQ (Cost of Poor Quality) Calculation

Number of pieces rejected last month
(for the part number identified for
study)
Number of pieces scrapped last month
Number of pieces reworked last month
Scrap cost/piece
Rework cost/piece
Total scrap cost (Rs. Lakhs) for last
month
Total rework cost(Rs. Lakhs) for last
month
Total Rejection cost (Rs. Lakhs) for last
month
Extrapolated Total rejection cost (Rs.
Lakhs) for one year

Note: Rejection should include both rework and scrap

Phase – 1- Problem Definition (Understanding the
problem)
Supporting data used in Problem understanding
Phase – 1- Problem Definition (Understanding the
problem)
Supporting data used in Problem understanding
 D
Define DEFINE
M&A 2. Data collection and analysis to identify the
Measure & possible causes for the problem
Analyse

I
Improve

C
Control
 Phase – 1- Problem Definition (Data collection and
analysis)
Machine Process parameter audit findings Date:
Selected: Shift:
Operator:

Process Standard Observed Conclusio Correction Permanent

parameter n action
 Phase – 1- Problem Definition (Data collection and
analysis)
Machine Machine and Tool condition audit findings Date:
Selected: Shift:
Operator:

Machine /Tool Condition Standard Observed Conclusion Actions

taken
Phase – 1- Problem Definition (Data collection and
analysis)

Monthly rejection trend for last 6 months

Double click on the graph to update the graph for your project
Phase – 1- Problem Definition (Data collection and
analysis)
Reasons for Abnormal rejections in Monthly analysis

Abnormal Possible reasons Actions taken

month
Phase – 1- Problem Definition (Data collection and
analysis)

Month:
Daily rejection trend for last month

Double click on the graph to update the graph for your project
Phase – 1- Problem Definition (Data collection and
analysis)
Reasons for Abnormal rejections in Daily analysis

Abnormal Possible reasons Actions taken

Day
 Phase – 1- Problem Definition (Data collection and
analysis)
Number of pieces tracked from each
machine:
Historic rejection %: Machine Pareto

Decide the lot quantity based on

historic rejection to get 30 bad
pieces Double click on the graph to update the graph for your project
Phase – 1- Problem Definition (Data collection and
analysis)
Reasons for Abnormality found in Machine pareto

Machine with Possible reasons Actions taken

more rejection
 Phase – 1- Problem Definition (Data collection and
analysis)
Number of pieces tracked from each
mould:
Historic rejection %:
Mould/Fixture Pareto

Decide the lot quantity based on

historic rejection to get 30 bad
pieces Double click on the graph to update the graph for your project
Phase – 1- Problem Definition (Data collection and
analysis)
Reasons for Abnormality found in Mould/Fixture pareto

Mould with Possible reasons Actions taken

more rejection
 Phase – 1- Problem Definition (Data collection and
analysis)
Number of pieces tracked from each
Operator:
Historic rejection %: Operator Pareto

Decide the lot quantity based on

historic rejection to get 30 bad
pieces Double click on the graph to update the graph for your project
Phase – 1- Problem Definition (Data collection and
analysis)
Reasons for Abnormality found in Operator pareto

Mould with Possible reasons Actions taken

more rejection
Phase – 1- Problem Definition (Data collection and
analysis)
Multivari analysis done to understand the pattern of variation

Pattern of How much?

variation
Part to Part

Time to Time

Stream to Stream

Stream to Stream

Stream to Stream
Conclusion:
 D
Define DEFINE
M&A 3. Identification of SSV’s (Suspected Sources
Measure & of variation)
Analyse

I
Improve

C
Control
 Phase – 1- Problem Definition (Identifying SSV’s)

Final list of Suspected Sources of Variation (SSV’s) for the physical

phenomenon of the problem

No. Suspected Sources of Variation (SSV’s) Design SSV or

Variation SSV
1
2
3
4
5
6
7
8
9
10
11
12
13

Transfer the above SSV’s to the next slide, write the tools you have used in the column and identify which tool has been used for which cause. Also write
the name of the tool in the Legend
 Phase – 1- Problem Definition (Identifying SSV’s)

Suspected Sources of Variations

B vs C
MVA
MCS

OBS
(SSV’s) for the physical

CC

VS
PPS

CS

FF
PC
phenomenon of the problem

PC – Paired Comparison, PPS – Product/Process search, CS – Component search MCS – Modified Component search MVA – Multivari analysis VS – Variable
search, FF – Full factorial, OBS – Observation, CC – Concentration chart