Satisfaction

Customer
Continual

Six Sigma Green Belt

Project Presentation

Soham Paul
mqms2214
 Define

November 14, 2023 Project Story Board 2

Define Capturing Voice of Customer

Customer Voice (in his own words) Customer

Children
Harry Styles Should fly stably with proper speed

Adam Roberts Colorful and attractive.

Jennifer Aniston Customizable Craftsmen

Draco Malfoy Affordable with good quality materials

Key inference / concept / Issue / learning

November 14, 2023 Project Story Board 3

Define Identifying CTQs

VOC Which CTQ(s) will be the primary

Customer (in his own words) CTQs
focus for this project?

Good quality Paper GSM • Paper GSM

Pranab Ghosh
materials (nominal) • Price per unit
• Lightweight
• Wing to body ratio
Price per unit <= Rs.
Sayan Pal Affordable
5

RK Sharma Easy to carry Light weight

Should fly stably Wing to body ratio,

Sumita Ganguly
with proper speed mass distribution

Key inference / concept / Issue / learning

November 14, 2023 Project Story Board 4

Define Project Charter
Business Case : The company was set up in June 2020, 3 months Scope :
after the covid lockdown with a vision to provide safe, affordable, easy • Increase the business throughout the state.
to play with paper helicopters for children. The covid lockdown was • Discounted sales in rural areas
exceptionally difficult for toddlers, so our vision is to provide them
• Adding LED lights is not in included in our scope.
with a toy that is safe, attractive, and can be used without parental
supervision.
Constraints
Goals & Objectives : To increase the sales by 5 times in the • Other competitors in the market like Hahacopter and
next 2 years. Flywell.
• Bulk production and Customizable • Not enough infrastructure for Bulk production
• Social Media promotions
• Easy booking through web applications
Team
• Management
Problem Statement : To create attractive, colorful, easy to • Production
play with paper helicopters which are safe for children • Sales and Marketing

Milestones
Benefits • Withing March’21 sales 2L
• Seller : Profit • Withing March’22 sales 5L
• Customer : Entertainment, happiness • Withing March’23 sales 8.5L

November 14, 2023 Project Story Board 5

 Define High Level Process Map

S I P O C Process Boundaries

Supplier Input Process Output Customer Start : Customer places an order

Finish : Product is delivered

AP Paper 1 Make Classic
Colorful measure Rainbow
mills
Paper ments Children Process Scope
limited Copter

In : Paper

ITC 2 Classic Out : Paper Helicopters

Cut Gothic
Papers A4 size Paper Copter
Limited paper Constraints
• Other competitors in the market like
Hahacopter and Flywell.
Craftsmen
• Not enough infrastructure for Bulk
JK Paper Scissors Copter production
and Fold
limited 3 Paper
Pro
Scale
Key inference / concept / Issue /
learning

November 14, 2023 Project Story Board 6

 Measure

November 14, 2023 Project Story Board 7

Measure Establishing Performance Variable
Performance Variables or CTQ Characteristics
Specifications
Variable Type
Sl. Performance Variable (CTQ Measurable or Remarks (If Any)
No Characteristics) Attribute
Target LSL USL

Flight Time Target is higher the

1 Measurable * 3 Sec *
better

November 14, 2023 Project Story Board 8

Measure Establishing Performance Standards

Y Flight Time

Measurable

Measuring Instrument-Stopwatch
LSL – 3 sec

Y Specifications Target - NA

USL - NA

November 14, 2023 Project Story Board 9

Measure Data Collection Plan
Sl.N Performance Type Measuring Data Remarks Check Sheets designed for the Data
o Variable (Continuous/ Specs Instrument Collection (if any)
Attribute) Plan collection purpose
1 Flight Time Continuous LSL = Stopwatch groups of
3s students No check sheets designed.
making and
“flying”
copters,
identified by
paper color,
where B= Whether data already available
blue, W =
white, Y = (secondary) or to be collected fresh
yellow.
each copter
design has a Data is collected first-hand.
unique ID.
Example:
design # 8 has
wing length =
65, body Precautions during data collections
width = 30,
and nonfolded
wings Data is collected under a controlled
environment inside a room without
much turbulence.

Key inference / concept / Issue /

learning

November 14, 2023 Project Story Board 10

Measure Measurement System Analysis

Sl. Measuring Accuracy Precision (G Action

Plan of MSA
No Instrument Variable Specs (Bias) R & R) Remarks if any
To assess the accuracy and repeatability of the
1 Stopwatch Flight Time LSL = ± 0.05 s timing method used to measure paper
3s helicopter flight time.

Controls identified and implemented

Implemented controls include standardized
drop height, consistent release technique, and
precise timing start and stop procedures to
minimize measurement system variability.

Precautions MSA

Ensure consistent environmental conditions

and minimize external influences during
measurement system analysis for paper
helicopter flight time

Key inference / concept / Issue / learning

November 14, 2023 Project Story Board 11

 Performance Evaluation
Measure (Stability Analysis)
Stability Diagnostics (Normality Testing)
Sl.N Performance Type Data Analysis
o Variable (C/A) Action & verification
Test Method Result (In case of There is no outlier in the dataset.
unstable process) All the data points are between 2.5s and 5.5s
1 Flight Time C Normal Follows
Probability Plot Normal
Distribution

Specific observations

Mean of the observations is 3.93s

And sd of the observations is 0.98

Outliers Removed (if any)

There is no outlier present in the dataset.

Key inference / concept / Issue / learning

November 14, 2023 Project Story Board 12

Measure Stability Diagnostics
Suggested Approach
+ Classify the variable (Continuous & discrete)
+ Perform appropriate tests for checking process stability (Run Chart, Histogram, Box Plot, NPP, Control
Charts)
+ The stability diagnostics should be preferably more than one type
+ Attach the corresponding graphs and interpret.

Key inference / concept / Issue / learning

November 14, 2023 Project Story Board 13

 Performance Evaluation
Measure (Capability Analysis)
Variable type

Specification
LSL – 3 sec

Tolerance Target - NA

Y USL- NA

Mean=4.04s
Descriptive Statistics
Sd=0.82

Cp =

Performance Metrics SL=2.77

Cpk=0.43

November 14, 2023 Project Story Board 14

 Analyze

November 14, 2023 Project Story Board 15

 Establish Performance Gap
Analyze (Benchmarking)
Performance Baseline Benchmark We need to reduce the SD so that the
Sl.No Variable Performance Performance Remarks
desired sigma level of 6 or higher can
be achieved.
Process
Sigma Level Sigma Level
Flight Time needs
1. = 2.77 =6
improveme
nt

Key inference / concept / Issue / learning

November 14, 2023 Project Story Board 16

Analyze Detailed Process Analysis
Suggested Approach Two major stages can be identified
● More detailed / Low level process mapping for the process variation-
● Mapping of all the Input-Processing-output variables, Value Stream
Mapping. 1. While designing and
manufacturing, due to
● Similar process analysis techniques to Understand the process
human and instrument error.
● Data analysis need to be carried out at appropriate stages to check 2. While flying it, due to air
for stability & capability. resistance, wind speed etc.
● Descriptive statistics, simple tools & techniques along with
diagnostics & graphs need to be used during analysis.
Process can be analyzed using
statistical softwares like

Minitab
Python
R

Key inference / concept / Issue / learning

November 14, 2023 Project Story Board 17

Cause Effect Diagram

November 14, 2023 Project Story Board 18

 Failure Mode and Effect Analysis

Failure mode Potential Cause(s) of failure Severity Occurrence Detectibility RPN Score
Manufacturing Factors
Human errors during assembly 7 5 9 315

Less Quality control 4 4 2 32

Folding varying from person to person 5 8 7 280

Inaccurate measurement while cutting 6 2 2 24

Design factors
Inaccurate wing to body ratio 9 1 1 9

Improper Wing shape 8 1 1 8

Environmental factors Different testing conditions 3 8 6 144

Variation in paper texture 5 4 1 20

Material Factors Variation in paper thickness 7 3 2 42

November 14, 2023 Project Story Board 19

 Potential Variation Sources
Analyze (Root Causes)
Suggested Approach Key aspects considered during
● Distinction in type of variation sources Assignable & Chance listing of the variation sources-
● Failure Mode Effect Analysis
● Brainstorming & C&E Diagram 1. Which are more severe
2. Which are more occurring
● List of potential variation sources
3. Which are less likely to get
detected

Sources not controllable-

1. Air resistance
2. Wind speed
3. Air pressure
4. Human errors, like shaking of
hands while releasing it.
These are semi controllable,
but not completely.

Key inference / concept / Issue / learning

November 14, 2023 Project Story Board 20

Analyze Establish Variation Sources
Suggested Approach Key aspects considered during root
● Statistical analysis to establish / validate the sources of variations cause analysis-
● Analytical/Statistical techniques used any selection / elimination. 1. Defining the problem clearly
● Postulating hypothesis to prove or disprove through tests. 2. Identifying the possible
sources of the problem via
● Diagnostics / Graphical methods.
brainstorming.
3. Identifying, among all the
possible causes, which are
more important.

Tools & Techniques used to establish

potential root causes-
1. Brainstorming
2. Cause and effect diagram
3. Severity, Occurrence and
detectability scores
4. RPN number and FMEA

Key inference / concept / Issue / learning

November 14, 2023 Project Story Board 21

 Improve

November 14, 2023 Project Story Board 22

Improve Discover Variable Relationships
Suggested Approach Key aspects considered during
● List of possible causes (Xs) for study relationship studies
● Search for Potential root causes
● Screening designs to identify the possible variables
● Analytical/Statistical tools and techniques to establish the
relationship between cause & effect (process variables &
performance variables)
● Study the transfer functions (if any)
● Graphical analysis (scatter plots) & Diagnostics
Tools & Techniques used to establish
relationships

Design & Analysis of Experiments

Key inference / concept / Issue / learning

November 14, 2023 Project Story Board 23

Improve Develop Optimum Solution
Suggested Approach Process Variables studied for
● Suggest possible solutions experimentation & Interactions-
● Study the alternate solutions 1. Time taken to land
Any innovative solution/variable can be tried out/introduced. 2. Height from which it is
●
released.
● Range in which the process variables can e tried out. 3. Dimensions of the copter.
● Experiment and suggest the optimum solution.
Countering the impact of Lurking
Variable (if any)-

1. Randomization of the design

2. Blocking

What is the strategy for noise -

Conducting the experiment in a wind

free zone, or in closed chambers to
reduce or block the effect of noise.

Key inference / concept / Issue / learning

November 14, 2023 Project Story Board 24

Improve Propose & Validate New Process
Suggested Approach Highlight the major process
● New process flow/SIPOC/Map changes-
● Study the potential failures (FMEA) 1. More stable process (i.e. Less
● Develop a deployment plan (if required) variance)
2. Very less data points that is
● Implement & pilot the process change
undesirable to customers (i.e.
● Validate the improvements (statistically) flight time more than or
equal to 3 seconds)

Methodology for validating-

1. Plotting control charts

2. Calculating variance using
statistical softwares or by
hand.

Key inference / concept / Issue / learning

November 14, 2023 Project Story Board 25

 Control

November 14, 2023 Project Story Board 26

Control Establish Improved Performance
● MSA for both Y’s & X’s if required Data collection plan
● Process Stability & Capability analysis
● Comparison of baseline, expected & observed ----

Performance Measures
Performance (Cp, Cpk, Sigma Level & DPMO)
Variable Specifications Remarks
Baseline Improved Gap Analysis (Expected &
Achieved)-

Current sigma level - 2.77

Flight Duration LSL = 3sec - - Expected sigma level - 6 or more

Key inference / concept / Issue / learning

November 14, 2023 Project Story Board 27

Control Control Plan

Project Customer
ABCD1234 Flight Time
Code CTQ
Process / Process
Flight Duration Enhancement XYZ Company
Sub Process Owner
Specifications
Variable Measuring Control
Sampling Control Actions on
Process Procedure out of control
to Control Devise System System/
Stage (SOP) situation
Target LSL USL plan

Repeat
Rational Process
Flight from
Control Stopwatch - 3 sec - SPC Subgroupi Stability
Time Analyze
ng Checking
Phase

Key inference / concept / Issue / learning

November 14, 2023 Project Story Board 28