1. Lean Six Sigma Greenbelt
Project B - Regrind
TEAM KAIZEN
TEAM NO 9
VENKATESH SRINIVASAN
BHAARAT KUMAR
PRAVEEN SUGURU
UKESH CHAWAL

2. DMAIC Define:
DEFINING THE PROBLEM:
 Consumption of extra material
 Only virgin material used
 Spruce and Runners were discarded
GOAL:
 Reduce virgin material consumption.
CONSTRAINTS:
 Dimensional changes are not significant.
 torque performance should not go below Cpk/Ppk of 1.25 minimum.

3. Measure:
Torque Test Capability
 Minimum breakage torque for Gear and Cam Fixture
 Gauge repeatability and reproducibility

4. Analyze:
 Dimensional Comparison
 Torque Capability Comparison Virgin Nylon vs Regrind
 Relationship of regrind percentage to breakage torque
 Capability Analysis for Gear and Cam Breakage
 Gage R&R Study – Nested ANOVA

5. Improve
 Improvements to fixture and test process

6. Control
 Statistical Process Control of Gear and Cam Breakage

7. Team Assumption
 Cost Analysis is given more priority than Cpk.
 Any Dimensional change less than 0.0005 are considered insignificant.

8. DELIVERABLES

9. CAPABILITY STUDY Cam 25% vs Cam 50%

10. CAPABILITY STUDY Cam 25% vs Cam 0%

11. CAPABILITY STUDY Gear 25% vs Gear 50%

12. CAPABILITY STUDY Gear 25% vs Gear 0%

13. REGRESSION MODEL

14. HYPOTHESIS TESTING

15. ANOVA TEST OF GRR 1 vs GRR 2 -
CAM

16. ANOVA TEST OF GRR 1 vs GRR 2 - GEAR

17. Economic Analysis

18. SPC

19. Conclusion
 25 % is better options than 50% and 0%.