The documentation problems on an initial build of 200 units for an ICE project resulted in $6,566.95 in costs. If left unaddressed, similar problems on a follow-on build of 1,060 units would cost an estimated $33,254.07. A 6 Sigma project team analyzed the root causes of the top documentation errors through surveys, 5 Whys analysis, and corrective action brainstorming. Implementing improvements such as automated data collection, streamlined test procedures, and consolidated paperwork storage reduced actual costs on the 1,060 unit build to $6,226.97, realizing estimated savings of $27,028.

1. ICE Raytheon 6 Sigma Project1
ICE Raytheon 6-Sigma Project

2. ICE Raytheon 6 Sigma Project2
ICE Raytheon 6-Sigma Project
VisualizeVisualize

3. ICE Raytheon 6 Sigma Project3
Documentation problems on the ICE project initial build of
200 units resulted in an estimated cost of $6,566.95.
Based on this information, the cost due to documentation
problems on the follow-on build of 1060 units would result
in a cost of $33,254.07 if the process is not corrected.
ProblemProblem
StatementStatement

4. ICE Raytheon 6 Sigma Project4
The deficiency rate for the build of
1060 final visual data package is
reduced by 90%, which equates to a
savings of $29928.66
VisionVision
StatementStatement

5. ICE Raytheon 6 Sigma Project5
GapGap
StatementStatement
The GAP due to Documentation Problems is
$29928.66 for the ICE Build of 1060 Units.
GAP
$33,254.07
$3,325.41
$0.00
$5,000.00
$10,000.00
$15,000.00
$20,000.00
$25,000.00
$30,000.00
$35,000.00
1 2
PRE POST
$ $ Amount

6. ICE Raytheon 6 Sigma Project6
ICE Raytheon 6-Sigma Project
CommitCommit

7. ICE Raytheon 6 Sigma Project7
Team MembersTeam Members
Tank Iyer
Steve Jackson
Chris Ernst
SponsorSponsor
Mike Padgett

8. ICE Raytheon 6 Sigma Project8
ICE Raytheon 6-Sigma Project
PrioritizePrioritize

9. ICE Raytheon 6 Sigma Project9
Data was collected via a survey
administered to all parties
involved in data package review
for the 1st
ICE build of 200.
People Surveyed Included:
Quality – Rich Gallien & John Jacobs
Technicians – Bob Patrick, Chris Ernst & Rob Bryzsky
Identify Constraints

10. ICE Raytheon 6 Sigma Project10
The following are some of the problems found at final visual:
 Erroneous / wrong data entry recorded.
 Missing paperwork.
 Extra paperwork.
 Wrong paperwork.
 Incomplete paperwork.
 Mixed S/N paperwork.
 Both test data and unit sub-assembly
 Massive volume of paper work with each unit.
 Irrelevant paper work left with the data package.
Initial Survey

11. ICE Raytheon 6 Sigma Project11
ICE DATA PACKAGE FAILURE SURVEY
During the 1st ICE build, Data Package collection/presentation to QC proved very problematic, causing delays in shipment
& requiring much non-value added time to be spent correcting the non-conformances. This survey has been created to
determine what major factors contributed to the Data Package Problems so that we may attempt to eliminate them on future
builds.
Since data associated with these failures was not recorded, this survey will attempt to quantify, more objectively, what the
cost of each major failure mode was. Therefore, after each question, please record what you believe the Frequency and
Time of each failure mode was. Please include any comments as to other failure modes believed to be important that have
not been listed on this survey.
Frequency (# of occurrences) Time (in Mins)
1) Erroneous/Wrong Data Recorded 90 29.83
2) Missing Paperwork 3 180
3) Extra Paperwork 50 10
4) Wrong Paperwork 3 30
5) Incomplete Paperwork 17 114.53
6) Mixed Serial Number Paperwork 10
30
(Both Test Data and Unit Sub-Assy)
7) Is the volume of paperwork appropriate? YES or NO
If NO, should there be MORE or could there be LESS?
Other Major Modes of Failure/Comments/Suggestions:
________________________________________________________________________
________________________________________________________________________
Initial Survey

12. ICE Raytheon 6 Sigma Project12
Survey Data Collection
Error Modes/Constraints # of Occurances Time Per Occurance (Mins) Total Time Per Failure Mode (Hours) Cost per Failure Mode*
Erroneous/Wrong Data Recorded 90 29.83 44.745 $2,908.43
Incomplete Paperwork 17 114.53 32.45016667 $2,109.26
Missing Paperwork 3 180 9 $585.00
Extra Paperwork 50 10 8.333333333 $541.67
Mixed S/N Paperwork 10 30 5 $325.00
Wrong Paperwork 3 30 1.5 $97.50
* a labor rate of $65/hour was assumed Total Cost $6566.85
$2,908.43
$585.00 $541.67
$325.00
$97.50
$2,109.26
44.29%
93.57%
98.52% 100.00%
76.41%
85.32%
$0.00
$500.00
$1,000.00
$1,500.00
$2,000.00
$2,500.00
$3,000.00
$3,500.00
Erroneous/Wrong Data
Recorded
Incomplete Paperwork Missing Paperwork Extra Paperwork Mixed S/N Paperwork Wrong Paperwork
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
Cost per failure mode
Cumulative Weight Line

13. ICE Raytheon 6 Sigma Project13
CharacterizeCharacterize
ICE Raytheon 6-Sigma Project

14. ICE Raytheon 6 Sigma Project14
5-Whys Tool
• Used to Characterize Root Causes Associated with
the Most Common Constraint.
ERRONEOUS/
WRONG DATA
RECORDED
Transcribed
Numbers
Illegible
Numbers
Too Much
Manual Data
Entry
Mis-Interpretation of
Data Displayed
Human
Error
Inexperienced
Techs
Poor
Penmanship Test Process
Not
Streamlined
Controlled
by Gov’t
Too
Much
Data
Collected
Some Data
Requires
Subjective
Interpretation
Not
Being
Careful
Contractual
Requirement
Human
Error

15. ICE Raytheon 6 Sigma Project15
5-Whys Tool
• Used to Characterize Root Causes Associated with
the 2nd
Most Common Constraint.
INCOMPLETE
PAPERWORK
Non-user
friendly
Forms
Voluminous
Quantity of
Forms
Human Error
Normal Authors (Test
Engineering) Not
Available to Write
Procedure
Unnecessary Tests
Operator Not
Being Careful

16. ICE Raytheon 6 Sigma Project16
5-Whys Tool
• Used to Characterize Root Causes Associated with
the 3rd
Most Common Constraint.
MISSING
PAPERWORK
Loose
Papers
Tough to Keep
Track of Due to
Volume of
Paperwork
Too Much
Handling
Physical Layout of
Facility (eg.
ESS/Vib Far From
Production)
Too
Much
Data
Collected
Contractual
Requirement
Mis-Handling
No Area on
Unit to Store
Paperwork
Human Error
Multiple People
Handling
Paperwork
Process
Required

17. ICE Raytheon 6 Sigma Project17
ICE Raytheon 6-Sigma Project
IMPROVEIMPROVE

18. ICE Raytheon 6 Sigma Project18
A BRAINSTORMING Session was Conducted on the Constraint Root
Causes Yielding the Following Corrective Actions.
ERRONEOUS/WRONG DATA RECORDED
ROOT CAUSE: CORRECTIVE ACTION:
Human Error Automate Data Recording Process
INCOMPLETE PAPERWORK
ROOT CAUSE: CORRECTIVE ACTION:
Unneccessary Tests/Human Error Converted Initial Test OP into Streamlined PD*
*Note: this saved an estimated 7-10 minutes/unit which
equates to an additional opportuny cost savings of
$8,000 - $11,500 (7 to 10 mins x 1060 units x $65/hour)
MISSING PAPERWORK
ROOT CAUSE: CORRECTIVE ACTION:
No Good Area on Unit to Store Paperwork ESD Sleeve Tie Wrapped to Box Handle
Human Error Go Paperless - Electronic Data Collection
Constraint->Root Cause->Corrective Action

19. ICE Raytheon 6 Sigma Project19
Automated Test Software Data Sheet
Note: This Solution Addresses the ESS Test Automation Action Item on the ICE Gate 5 Risk & Opportunity Matrix
Corrective Action for the Root Cause of the 1st
Constraint

20. ICE Raytheon 6 Sigma Project20
• PD for Initial Test Procedure
Corrective Action for the Root Cause of the 2nd
Constraint

21. ICE Raytheon 6 Sigma Project21
ESD Safe Sleeve for Consolidation of Paperwork
BEFORE
AFTER
Corrective Action for the Root Cause of the 3rd
Constraint

22. ICE Raytheon 6 Sigma Project22
ACHIEVEACHIEVE
• Data collected by inspectors at final visual by
survey.
• Data was collected from March 28 through April
21 on a total of 540 units.

23. ICE Raytheon 6 Sigma Project23
Survey ResultsFinal Visual Deficiency Collection Sheet
Place a tally mark for every unit with deficiencies in the
proper column.
Total # of units visualed 540
1 Erroneous/Wrong Data Recorded
Vibration 2
ESS 1
Final Operational 0
*** Other (Specify on back) 0
2 Missing Paperwork
Vibration 0
ESS 0
Final Operational 0
*** Other (Specify on back) 0
3 Extra/non-required Paperwork
Vibration 0
ESS 0
Final Operational 0
*** Other (Specify on back) 0
4 Wrong Paperwork
Vibration 0
ESS 0
Final Operational 0
*** Other (Specify on back) 0
5 Incomplete Paperwork
Vibration 21
ESS 1
Final Operational 2
*** Other (Specify on back) 0
6 Mixed S/N Paperwork
Vibration 0
ESS 0
Final Operational 0
*** Other (Specify on back) 0
#2. This is paperwork that needs to be present but is missing
#3. This is paperwork that is present and should not be.
Name:_____________________________
Date:_____________

24. ICE Raytheon 6 Sigma Project24
EXTRAPOLATED COST (ON RUN OF 1060 if Nothing was Done)
Error Modes/Constraints # of Occurances Time Per Occurance (Mins) Total Time Per Failure Mode (Hours) Cost per Failure Mode*
Erroneous/Wrong Data Recorded 477 29.83 237.15 $15,414.65
Incomplete Paperwork 90.1 114.53 171.99 $11,179.08
Missing Paperwork 15.9 180 47.70 $3,100.50
Extra Paperwork 265 10 44.17 $2,870.83
Mixed S/N Paperwork 5.3 30 2.65 $172.25
Wrong Paperwork 15.9 30 7.95 $516.75
* a labor rate of $65/hour was assumed $33,254.07
""ACTUAL" COST ON RUN OF 1060 - based on a sample of 540 units (data was normalized to 1060 Units)
Error Modes/Constraints # of Occurances Time Per Occurance (Mins) Total Time Per Failure Mode (Hours) Cost per Failure Mode*
Erroneous/Wrong Data Recorded 6 29.83 2.93 $190.30
Incomplete Paperwork 47 114.53 89.93 $5,845.27
Missing Paperwork 0 180 0.00 $0.00
Extra Paperwork 0 10 0.00 $0.00
Mixed S/N Paperwork 0 30 0.00 $0.00
Wrong Paperwork 6 30 2.94 $191.39
* a labor rate of $65/hour was assumed $6,226.97
$0.00
$2,000.00
$4,000.00
$6,000.00
$8,000.00
$10,000.00
$12,000.00
$14,000.00
$16,000.00
$18,000.00
Erroneous/ Wrong
Dat a Recorded
Incomplet e
Paperwork
Missing Paperwork Ext ra Paperwork Wrong Paperwork Mixed S/ N
Paperwork
Run of 1060 (Est)
Run of 1060 (Act)

25. ICE Raytheon 6 Sigma Project25
• The data in RED shows the “risk” cost of data failures on
the run of 1060 (if nothing was done) = $33,255.
• The data in GREEN shows the “actual” cost after
implementing the corrective action = $6,227 (Note: data
based on 540 units sampled & normalized to 1060).
• Therefore, the achieved “opportunity” cost savings over
1060 units = $27,028 + ($8,000 Initial Op Test PD
savings) = $35,028.
$0.00
$2,000.00
$4,000.00
$6,000.00
$8,000.00
$10,000.00
$12,000.00
$14,000.00
$16,000.00
$18,000.00
Erroneous/ Wrong
Dat a Recorded
Incomplet e
Paperwork
Missing Paperwork Ext ra Paperwork Wrong Paperwork Mixed S/ N
Paperwork
Run of 1060 (Est)
Run of 1060 (Act)

26. ICE Raytheon 6 Sigma Project26
Lessons LearnedLessons Learned
• R6-Sigma is a “real” process
– It takes effort to do it right.
• 5-Whys are not always as easy as they seem
– Stay focused on the actionable root causes.
• Stay disciplined: Work through ALL the steps
– Avoid jumping to the root cause/corrective action too quickly.
• Base findings on Data
– Don’t force personal opinions into the analysis.
• With the appropriate buy-in, anything is possible
– E.g. Changed initial op test into a PD.