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.
This document describes a project to reduce scrap rates in piston casting at a foundry from 7% to 2% over 4 months using optimization techniques. The foundry casts pistons for Tata trucks. Testing of process parameters like cooling time, gate size, water temperature and metal temperature identified relationships to reduce scrap. Statistical modeling determined the optimal settings were a cooling time of 47 seconds, gate size of 132 mm^2, water temperature of 32°C and metal temperature of 792°C to minimize scrap to an estimated 5.28%. The document recommends applying fuzzy logic, genetic algorithms or artificial intelligence to further improve the optimization model.
Push And Pull Production Systems Chap7 Ppt)3abooodi
The document discusses push and pull production control systems. A push system like MRP initiates production based on forecasts, while a pull system like JIT initiates production based on current demand. MRP involves gathering demand data, determining planned order releases using explosion calculus, and developing shop floor schedules. Lot sizing algorithms aim to balance setup and holding costs. Capacity constraints and improvement steps can further optimize production planning.
The project is based on detecting frequent patterns on a web-server by using the server log. It generates multi-level statistics based on Apriori algorithm with each level determined by Pattern length.
Currently this is a dynamic programming form of Apriori where we have implemented the rule that to be a frequent pattern at a level k (i.e patter of size k), one of the elements from its powerset of size (k-1) must be frequent. This helps in improving the efficiency to less than quadratic time on average.
The document discusses push and pull production control systems. A push system like MRP initiates production based on forecasts, while a pull system like JIT initiates production in response to current demand. MRP breaks down a master production schedule into detailed component schedules using bill of materials explosion and lot sizing algorithms. It incorporates demand forecasts, safety stocks, and other factors to determine planned order releases. The goal is to minimize costs by balancing set up costs with holding costs.
Conceptual Model on Physical Resilience Contributes to Hospital-Community Tra...Rafael Bernardes
Este documento discute um algoritmo para avaliar a resiliência e capacidade funcional de pacientes na transição entre o hospital e a casa. O algoritmo avalia os pacientes na admissão e alta hospitalar e após a alta para determinar o melhor plano de cuidados e continuidade de cuidados. O objetivo é melhorar a capacidade funcional dos pacientes, reduzir readmissões hospitalares e evitar institucionalização a longo prazo.
Jesse Arreguin has accomplished a great deal as a member of the Berkeley City Council over the past 6 years. Some of his major accomplishments include adopting policies around balcony inspections after a tragic balcony collapse, establishing a progressive community benefits package for new developments, adopting fair and impartial policing policies to address discriminatory policing, increasing the minimum wage, and changing the city's vehicle impound policy in response to concerns of the undocumented community. He has also worked on issues like restricting predatory lending, banning discrimination in hiring, opting out of Secure Communities to protect undocumented immigrants, establishing an affordable housing mitigation fee, and regulating tenant screening fees.
El documento resume temas sobre el enamoramiento, desamor, amor a distancia, sexualidad y toma de decisiones durante la adolescencia. Explica que el enamoramiento se basa en la comunicación emocional, física e intelectual entre dos personas y puede ser externo o interno. También describe el proceso del enamoramiento y la necesidad que sienten los adolescentes por enamorarse. Aborda después el desamor, amor a distancia y la importancia de la sexualidad durante la adolescencia, así como la necesidad de satisfacción sexual y la toma de decisiones sobre la
This document provides vocabulary pre-teaching for the story "Alexander, Who Used to Be Rich Last Sunday". It defines and provides examples for the words: absolutely, positively, vanish, tokens, lox, and smushed. It also includes a matching activity to match vocabulary words with their definitions.
This document describes a project to reduce scrap rates in piston casting at a foundry from 7% to 2% over 4 months using optimization techniques. The foundry casts pistons for Tata trucks. Testing of process parameters like cooling time, gate size, water temperature and metal temperature identified relationships to reduce scrap. Statistical modeling determined the optimal settings were a cooling time of 47 seconds, gate size of 132 mm^2, water temperature of 32°C and metal temperature of 792°C to minimize scrap to an estimated 5.28%. The document recommends applying fuzzy logic, genetic algorithms or artificial intelligence to further improve the optimization model.
Push And Pull Production Systems Chap7 Ppt)3abooodi
The document discusses push and pull production control systems. A push system like MRP initiates production based on forecasts, while a pull system like JIT initiates production based on current demand. MRP involves gathering demand data, determining planned order releases using explosion calculus, and developing shop floor schedules. Lot sizing algorithms aim to balance setup and holding costs. Capacity constraints and improvement steps can further optimize production planning.
The project is based on detecting frequent patterns on a web-server by using the server log. It generates multi-level statistics based on Apriori algorithm with each level determined by Pattern length.
Currently this is a dynamic programming form of Apriori where we have implemented the rule that to be a frequent pattern at a level k (i.e patter of size k), one of the elements from its powerset of size (k-1) must be frequent. This helps in improving the efficiency to less than quadratic time on average.
The document discusses push and pull production control systems. A push system like MRP initiates production based on forecasts, while a pull system like JIT initiates production in response to current demand. MRP breaks down a master production schedule into detailed component schedules using bill of materials explosion and lot sizing algorithms. It incorporates demand forecasts, safety stocks, and other factors to determine planned order releases. The goal is to minimize costs by balancing set up costs with holding costs.
Conceptual Model on Physical Resilience Contributes to Hospital-Community Tra...Rafael Bernardes
Este documento discute um algoritmo para avaliar a resiliência e capacidade funcional de pacientes na transição entre o hospital e a casa. O algoritmo avalia os pacientes na admissão e alta hospitalar e após a alta para determinar o melhor plano de cuidados e continuidade de cuidados. O objetivo é melhorar a capacidade funcional dos pacientes, reduzir readmissões hospitalares e evitar institucionalização a longo prazo.
Jesse Arreguin has accomplished a great deal as a member of the Berkeley City Council over the past 6 years. Some of his major accomplishments include adopting policies around balcony inspections after a tragic balcony collapse, establishing a progressive community benefits package for new developments, adopting fair and impartial policing policies to address discriminatory policing, increasing the minimum wage, and changing the city's vehicle impound policy in response to concerns of the undocumented community. He has also worked on issues like restricting predatory lending, banning discrimination in hiring, opting out of Secure Communities to protect undocumented immigrants, establishing an affordable housing mitigation fee, and regulating tenant screening fees.
El documento resume temas sobre el enamoramiento, desamor, amor a distancia, sexualidad y toma de decisiones durante la adolescencia. Explica que el enamoramiento se basa en la comunicación emocional, física e intelectual entre dos personas y puede ser externo o interno. También describe el proceso del enamoramiento y la necesidad que sienten los adolescentes por enamorarse. Aborda después el desamor, amor a distancia y la importancia de la sexualidad durante la adolescencia, así como la necesidad de satisfacción sexual y la toma de decisiones sobre la
This document provides vocabulary pre-teaching for the story "Alexander, Who Used to Be Rich Last Sunday". It defines and provides examples for the words: absolutely, positively, vanish, tokens, lox, and smushed. It also includes a matching activity to match vocabulary words with their definitions.
En 3 oraciones:
El documento presenta fórmulas para determinar el tamaño de muestra para poblaciones infinitas y finitas. Incluye los niveles de confianza comúnmente usados y cómo calcular el margen de error. Además, proporciona un ejemplo numérico para ilustrar cómo aplicar la fórmula del margen de error.
El documento habla sobre la educación virtual. Explica que la integración curricular de las tecnologías de la información implica el uso de estas tecnologías para lograr un objetivo educativo específico. También describe algunas características de la educación virtual como ser flexible, individualizada e interactiva y que permite el acceso a gran cantidad de información actualizada. Finalmente, concluye que el uso de las tecnologías rescata el contexto espacio-temporal en los procesos de enseñanza-aprendizaje.
When presented in 2010, this presentation provided a novel concept for moving from passive security to active defense. Leveraging lessons learned from BearingPoint and Deloitte's R&D on Collaborative Situational Awareness for Decision Making, this presentation put forward a framework for integrating cyber security system to enhance collaboration and more effectively integrate information from desperate sources.
Firebase para se divertir com Internet das CoisasLuís Leão
O documento discute como prototipar projetos de Internet das Coisas de forma divertida usando ferramentas como Firebase, Johnny-Five e Arduino/Raspberry Pi. A palestrante apresenta como desenvolvedores web podem trabalhar com eletrônica e fornece uma receita para projetos de IoT usando esses recursos.
This document discusses various methods for controlling water and gas coning in oil wells, including dual completions, chemical treatments, and downhole water sink (DWS) technology. DWS involves installing a second completion below the oil-water contact to drain and produce water, preventing it from coning into the main oil zone. It has been shown to effectively control coning through creating a hysteresis effect. While simple to implement, DWS may not be economical for low-producing wells. Overall, DWS appears to be one of the most effective methods for retarding unwanted water and gas influx compared to alternatives like producing below critical rates or using polymers that can damage the reservoir.
The document describes research to optimize the time and cost efficiency of assembling desktop computers for Delta's Electronics. A critical path analysis determined the minimum time to assemble a computer is 77 minutes. A Hungarian algorithm was used to allocate parts purchases across 5 stores to minimize total costs, determining the optimal allocation that results in a total cost of $2341. The analysis provides Delta's Electronics with ways to improve the assembly process time and reduce costs.
This document provides an overview of supply chain design and operations presented by Anqi Guo. It discusses where the presenter obtained their background from, including education and past clients. The content covers introductions to operations research and its applications in supply chain design. Case studies are presented on revitalizing a manufacturing company, designing a bike rental system, and improving a pharmacy supply chain for distributing antiviral drugs. Brief details are given on Amazon's use of algorithms to predict and stock popular products before customer orders.
IRJET- A Case Study Approach of Quality Tools in Manufacturing IndustryIRJET Journal
This document summarizes a case study on using quality tools to improve manufacturing processes at a company. The study focused on an oscillator product that was experiencing high defect rates, excess manufacturing time, and decreased productivity.
The researchers used Six Sigma's DMAIC methodology to define, measure, analyze, improve, and control the manufacturing process. In the define phase, they mapped the manufacturing process and identified issues like long cycle times, excess assembly time, and reworks. In measure, they collected time and quality data. Analysis found some operations took longer than the calculated takt time and elements had dimensional variations, leading to defects. Pareto analysis showed milling and CNC operations contributed most defects. The goal is to improve these
1. The document discusses using graphics and data visualization to improve understanding of database performance issues and SQL tuning. It provides examples of how visualizations can clearly show relationships in complex SQL queries and data that are difficult to understand from text or code alone.
2. Key steps in visual SQL tuning are laid out, including drawing tables as nodes, joins as connection lines, and filters as markings on tables. This helps identify optimization opportunities like missing indexes or stale statistics.
3. The document emphasizes that a lack of clarity in visualizing complex data and queries can have devastating consequences, while graphics enable easy understanding and effective problem-solving.
The document discusses the concept of Overall Equipment Effectiveness (OEE) and how to calculate it. OEE is a measure of how well a manufacturing line or equipment is utilized compared to its full potential. It is calculated by multiplying three individual rates: operating rate, performance rate, and quality rate. The document provides examples and calculations to demonstrate how to determine a line's OEE based on production data, downtime, and standard cycle times.
The document provides a root cause analysis for a failure that occurred during a trial run of a new fiber optic cable product called TruWave. The summary is:
1) A failure occurred on June 1st during a trial run of the TruWave cable where the polyethylene jacketing was deformed and tearing in some areas.
2) An investigation found the root cause was operator error, where the technician manually entered an incorrect temperature of 400 degrees instead of the required 525 degrees for melting the polyethylene properly.
3) To prevent future errors, the corrective action is to pre-program trial run cable process parameters into the line computers rather than having technicians manually enter them.
The document outlines a study being conducted by Opinion Dynamics Corporation to assess Concord Light Company's (CLC) energy efficiency potential and program opportunities. The study will involve collecting primary data from CLC customers, developing an energy efficiency potential model, and providing recommendations to support CLC's commercial/industrial programs. Key tasks include planning the study, conducting surveys and site visits, building an energy savings model, analyzing results, and assisting with program design. The goals are to document CLC's efficiency penetration, estimate remaining savings potential, and inform CLC's next three-year energy plan.
PPT Item # 5&6 - Water & Sewer Rate Studyahcitycouncil
The document provides information on a proposed rate update and meter assessment for a city council presentation. It summarizes meter testing results that found 12.7% inaccuracy across the current meter population. It compares the costs of upgrading the metering system to a cellular or fixed network option over 20 years, finding cellular to be more cost effective. Cashflow projections show a cellular network upgrade could be financially self-sustaining with limited capital contributions, and grant funding could provide substantial benefits including surplus cashflow.
The document summarizes the efforts of a team to improve the rigid laminate scheduling system at a manufacturing plant. Key changes included decoupling scheduling from sales orders, scheduling the press based on the top 5 master sheet parts to better manage variation, and batching odd rigid orders to be processed twice per month. These changes reduced unnecessary changeovers, late shipments, and inventory levels. Metrics showed improvements like a 14% increase in plant capacity and a 13% reduction in master sheet work-in-process inventory.
Ways to minimise performance risks in continuous deliverya32an
This document discusses ways to minimize performance risks with continuous delivery. It recommends focusing on fast recovery from failures rather than preventing them. Traditional load testing is replaced with permanent load testing on production-like environments and monitoring impacts of changes. Architectures should be simple and flexible to enable rapid deployment of changes and recovery from failures. Culture and collaboration between development and operations are important to make data-driven decisions based on measurements of technical and business metrics.
En 3 oraciones:
El documento presenta fórmulas para determinar el tamaño de muestra para poblaciones infinitas y finitas. Incluye los niveles de confianza comúnmente usados y cómo calcular el margen de error. Además, proporciona un ejemplo numérico para ilustrar cómo aplicar la fórmula del margen de error.
El documento habla sobre la educación virtual. Explica que la integración curricular de las tecnologías de la información implica el uso de estas tecnologías para lograr un objetivo educativo específico. También describe algunas características de la educación virtual como ser flexible, individualizada e interactiva y que permite el acceso a gran cantidad de información actualizada. Finalmente, concluye que el uso de las tecnologías rescata el contexto espacio-temporal en los procesos de enseñanza-aprendizaje.
When presented in 2010, this presentation provided a novel concept for moving from passive security to active defense. Leveraging lessons learned from BearingPoint and Deloitte's R&D on Collaborative Situational Awareness for Decision Making, this presentation put forward a framework for integrating cyber security system to enhance collaboration and more effectively integrate information from desperate sources.
Firebase para se divertir com Internet das CoisasLuís Leão
O documento discute como prototipar projetos de Internet das Coisas de forma divertida usando ferramentas como Firebase, Johnny-Five e Arduino/Raspberry Pi. A palestrante apresenta como desenvolvedores web podem trabalhar com eletrônica e fornece uma receita para projetos de IoT usando esses recursos.
This document discusses various methods for controlling water and gas coning in oil wells, including dual completions, chemical treatments, and downhole water sink (DWS) technology. DWS involves installing a second completion below the oil-water contact to drain and produce water, preventing it from coning into the main oil zone. It has been shown to effectively control coning through creating a hysteresis effect. While simple to implement, DWS may not be economical for low-producing wells. Overall, DWS appears to be one of the most effective methods for retarding unwanted water and gas influx compared to alternatives like producing below critical rates or using polymers that can damage the reservoir.
The document describes research to optimize the time and cost efficiency of assembling desktop computers for Delta's Electronics. A critical path analysis determined the minimum time to assemble a computer is 77 minutes. A Hungarian algorithm was used to allocate parts purchases across 5 stores to minimize total costs, determining the optimal allocation that results in a total cost of $2341. The analysis provides Delta's Electronics with ways to improve the assembly process time and reduce costs.
This document provides an overview of supply chain design and operations presented by Anqi Guo. It discusses where the presenter obtained their background from, including education and past clients. The content covers introductions to operations research and its applications in supply chain design. Case studies are presented on revitalizing a manufacturing company, designing a bike rental system, and improving a pharmacy supply chain for distributing antiviral drugs. Brief details are given on Amazon's use of algorithms to predict and stock popular products before customer orders.
IRJET- A Case Study Approach of Quality Tools in Manufacturing IndustryIRJET Journal
This document summarizes a case study on using quality tools to improve manufacturing processes at a company. The study focused on an oscillator product that was experiencing high defect rates, excess manufacturing time, and decreased productivity.
The researchers used Six Sigma's DMAIC methodology to define, measure, analyze, improve, and control the manufacturing process. In the define phase, they mapped the manufacturing process and identified issues like long cycle times, excess assembly time, and reworks. In measure, they collected time and quality data. Analysis found some operations took longer than the calculated takt time and elements had dimensional variations, leading to defects. Pareto analysis showed milling and CNC operations contributed most defects. The goal is to improve these
1. The document discusses using graphics and data visualization to improve understanding of database performance issues and SQL tuning. It provides examples of how visualizations can clearly show relationships in complex SQL queries and data that are difficult to understand from text or code alone.
2. Key steps in visual SQL tuning are laid out, including drawing tables as nodes, joins as connection lines, and filters as markings on tables. This helps identify optimization opportunities like missing indexes or stale statistics.
3. The document emphasizes that a lack of clarity in visualizing complex data and queries can have devastating consequences, while graphics enable easy understanding and effective problem-solving.
The document discusses the concept of Overall Equipment Effectiveness (OEE) and how to calculate it. OEE is a measure of how well a manufacturing line or equipment is utilized compared to its full potential. It is calculated by multiplying three individual rates: operating rate, performance rate, and quality rate. The document provides examples and calculations to demonstrate how to determine a line's OEE based on production data, downtime, and standard cycle times.
The document provides a root cause analysis for a failure that occurred during a trial run of a new fiber optic cable product called TruWave. The summary is:
1) A failure occurred on June 1st during a trial run of the TruWave cable where the polyethylene jacketing was deformed and tearing in some areas.
2) An investigation found the root cause was operator error, where the technician manually entered an incorrect temperature of 400 degrees instead of the required 525 degrees for melting the polyethylene properly.
3) To prevent future errors, the corrective action is to pre-program trial run cable process parameters into the line computers rather than having technicians manually enter them.
The document outlines a study being conducted by Opinion Dynamics Corporation to assess Concord Light Company's (CLC) energy efficiency potential and program opportunities. The study will involve collecting primary data from CLC customers, developing an energy efficiency potential model, and providing recommendations to support CLC's commercial/industrial programs. Key tasks include planning the study, conducting surveys and site visits, building an energy savings model, analyzing results, and assisting with program design. The goals are to document CLC's efficiency penetration, estimate remaining savings potential, and inform CLC's next three-year energy plan.
PPT Item # 5&6 - Water & Sewer Rate Studyahcitycouncil
The document provides information on a proposed rate update and meter assessment for a city council presentation. It summarizes meter testing results that found 12.7% inaccuracy across the current meter population. It compares the costs of upgrading the metering system to a cellular or fixed network option over 20 years, finding cellular to be more cost effective. Cashflow projections show a cellular network upgrade could be financially self-sustaining with limited capital contributions, and grant funding could provide substantial benefits including surplus cashflow.
The document summarizes the efforts of a team to improve the rigid laminate scheduling system at a manufacturing plant. Key changes included decoupling scheduling from sales orders, scheduling the press based on the top 5 master sheet parts to better manage variation, and batching odd rigid orders to be processed twice per month. These changes reduced unnecessary changeovers, late shipments, and inventory levels. Metrics showed improvements like a 14% increase in plant capacity and a 13% reduction in master sheet work-in-process inventory.
Ways to minimise performance risks in continuous deliverya32an
This document discusses ways to minimize performance risks with continuous delivery. It recommends focusing on fast recovery from failures rather than preventing them. Traditional load testing is replaced with permanent load testing on production-like environments and monitoring impacts of changes. Architectures should be simple and flexible to enable rapid deployment of changes and recovery from failures. Culture and collaboration between development and operations are important to make data-driven decisions based on measurements of technical and business metrics.
The presentation on Batch Workload Modelling and Performance Optimization was done during #ATAGTR2017, one of the largest global testing conference. All copyright belongs to the author.
Author and presenter : Ashish Powar
The document provides 7 examples of statistical analyses and distributions. Example 1 involves drawing a histogram for discrete vehicle arrival data collected over multiple days. Example 2 involves drawing a histogram for continuous component lifetime data. Example 3 involves estimating parameters and variance for discrete vehicle arrival data. Example 4 involves determining if installation time data follows a normal distribution. Example 5 involves estimating parameters for a lognormal model of investment rate data. Example 6 involves using a chi-square test to determine if discrete vehicle arrival data follows a Poisson distribution. Example 7 involves using a chi-square test to determine if mine injury count data follows a Poisson distribution.
Using artificial intelligence algorithms and machine learning techniques, ToPa 3D was able to identify the center point of each nursery plant pot in the ground for precision trimming operations. This saved Woodburn Nursery time and money to ensure their operation maintained maximum efficiency
This document provides guidance on calculating and interpreting the process capability index Cpk. It defines Cpk as a ratio that compares the specification tolerance to the process variation expressed in terms of standard deviations. It explains how to calculate Cpk and discusses factors that influence Cpk values such as sample size, process centering, and measurement uncertainty. The document also provides examples of the expected defective parts per million that correspond to different Cpk values and factors to consider when improving Cpk, such as machine, tooling, workholding, and workpiece variables.
This document discusses advances in fault detection and diagnosis in industry. It covers condition monitoring techniques like vibration analysis, lubricant analysis, and thermography. It discusses the differences between fault, failure, and malfunction and describes fault detection as detecting small faults early through techniques like limit checking and trend analysis. Fault diagnosis involves diagnosing faults in processes, parts, and devices using analytical and heuristic methods. Condition monitoring systems are discussed along with fault detection models using process variables. Data analysis techniques and online enterprise asset management are also covered.
In this Dagstuhl talk, I presented my current research on cloud auto-scaling and component connector self-adaptation and how I employed type-2 fuzzy control to tame the uncertainty regarding knowledge specification.
PG&E plans to survey nearly 500,000 gas services in 2015 using advanced leak detection technology. The document analyzes the variables and costs associated with performing the surveys using the new technology. It estimates that performing 8 surveys could find over 68,000 leaks at a total cost of around $22 million, including capital investment, survey costs, and investigation and grading of leaks found. It also models how finding more leaks could reduce the monetary risk from undetected hazardous leaks.
Eric Katzen worked as an intern at NASA's Hazardous Gas Detection Laboratory (HGDL) under the mentorship of electrical engineer Reggie Martin. Some of his responsibilities included developing leak test equipment, procedures, and calibrating helium mass spectrometers. Specifically, he developed a Leak Tester Cart to test for leak rates, amended HGDL procedures to conform with industry standards, calibrated helium mass spectrometers, tested fittings for maximum leak rates, and created a webpage organizing leak detection specifications and standards. Through his work, he gained valuable experience in leak detection techniques and helping improve HGDL testing operations.
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
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
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
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.