John Q Public completed a Six Sigma project from January 2006 to March 2006 to reduce quality defects in the XXX process at Never Fail Inc. The process was producing over 20% defects, resulting in customer complaints, inconsistent delivery, and increased costs. The goal was to reduce defects to under 0.5% while achieving 99% on-time delivery. As black belt, John created project documents, led a team through analysis tools including process mapping, DOE, and capability studies to identify and optimize significant factors. This reduced defects and improved customer satisfaction. The project saved $250,000 annually in material and labor costs by reducing scrap and improving capacity for on-time delivery. Bruce Almighty, Operations Director at Never Fail Inc., verified

1. A Sample filled in CSSBB affidavit
1. Six Sigma Project completed by John Q Public, 01000010
(applicant’s name, please print) (member number)
2. Six Sigma project title Reduction of XXX process Quality defects
3. Provide a brief description of the purpose of the project, and how it related to the business
objective:
The process XXX has been our bottle neck for over 6 months producing defects over 20 % of the
manufacturing volume. This excess defectives have resulted in customer complaints (Inspection
escape), inconsistent delivery, and increasing in manufacturing costs. This goal for this process
step is to keep the defectives under 5000 ppm (0.5%) The on-time delivery of correct quantity is
expected to be 99% or higher. By improving the process quality to less than 5000 ppm, and
building adequate controls in place, the number escape defects are expected to reduce to less
than 500 ppm.
4. Six Sigma project’s start and completion dates by month/year: Jan 2006- March 2006
5. Provide a brief description of applicant’s hands-on performance in completing Six Sigma
project. Please include specific examples of tools used, i.e., process maps, metrics (DPU, DPMO,
RTY), procedures, charts, etc. Do not send documentation.
As a Black belt, I was responsible for creating a project charter to define the project, NPV
financial sheet to calculate project financial gains, develop a comprehensive Project plan (Gantt).
I lead the team with a brainstorming session, consolidated the inputs to a cause and effect
diagram. The process map and initial data of process defect Pareto analysis were used during
the discussion. Prioritized causes were further investigated to identify the root causes.
Measurement system analysis was conducted to identify the measurement system error; a
factorial DOE was conducted to identify significant factors. A Response surface design was
further used to optimize the process settings. The process capability study was conducted and
the indices Cp, Cpk were meeting the process objectives. The team developed on the existing
PFMEA and updated the control plan for sustainability.
6. Provide a brief statement on the benefits achieved by the successful completion of the project,
including but not limited to financial savings, labor, material costs, cycle-time reduction, etc.
The process step with the initial process defectives at 20% was costing the organization $5000 /
Week (over $250,000 / year). This includes material costs and labor only. The lost machine
capacity in producing scrap is now effectively used for meeting tighter delivery deadlines. The
reduced escape defects and on-time delivery have improved our customer satisfaction from 3.5 to
4.0 in a 5 point scale.
The NPV, ROI, payback financial sheet were verified by MBB.
7. Verification of completion by project champion:
Verification form completed by:
Bruce Almighty 11th
April 2006
(project champion’s signature) (date signed)
Champion’s name: Bruce Almighty Job title Operations Director
Company name Never Fail Inc.
Address 1, Zero defect Lane, Road to success, Achievement Valley, California
Project champion’s e-mail address bruce.almighty@neverfail.com
Project champion’s telephone 408 1234567 Fax number 408 1234568.
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Author: Govind Ramu