Workorder Error Reduction Six Sigma Case Study

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Six Sigma Project Case Study Overview by Master Black Belt Steven Bonacorsi, International Standard for Lean Six Sigma (ISLSS). General Electic ACFC "At the Customer, for the Customer"

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Workorder Error Reduction Six Sigma Case Study

  1. 1. Six Sigma DMAIC Project GE Aircraft Engines Account Project Leader/Green Belt: Dave Smith Project Leader Title: Solution Design Consultant Project Start Date: May 21, 2003Master Black Belt: Steven Bonacorsi
  2. 2. Six Sigma in Action Work Order Error CorrectionCustomer Profile – 17,000 Seat, Global design & production company for Aircraft EnginesBusiness Problem & Impact Process Capability – BeforeFixed assets work order scanning (barcode) inherently introduces errors.Multiple individuals use the existing process, which causes 40 - 50% 65 (9%)error rate. The existing process is not cost effective, since errors are Defects 628 (91%)corrected manually. SuccessfulMeasure & AnalyzeData Collection:Historical data was collected over a 1 month period to quantify the extentof errors. Z_ST = 1.3Root Causes:Serial Numbers for IBM T30 laptops and DELL monitors fail import everytime and barcode being different between the shipping box andequipment were determined to be root causes. Process Capability – AfterImprove & Control Baseline ImprovedReal Time scanning was implemented to in December 2003. Scanner Units 693 240accuracy will be monitored daily and control charts will be used Qrtly to Defects 85 0validate process improvements. DPMO 93,795 0Results/Benefits Z (ST) 2.82 6.0At the end of the project, real time scanning reduced rework 100% andcycle time per hardware component reduced from 10 to 5 seconds Z (LT) 1.32 4.5resulting in annual efficiency savings of >9.7 K! A savings of US $9,716 in 2003!

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