Problem Statement:
Lower than expected billability, also described as Excessive Bench Capacity, results in chargeability variances and negatively impacts services margins by approximately $100,000,000 per year.
Goal Statement:
Improve billability from current 60% to 70% while maintaining planned fee adjustment. Corrective action plan will be prepared by June 200X, implemented by July 200X. Benefits will be evaluated 6 and 12 months following implementation.
The owner company is developing the Phase II of the Jubail Industrial City in Saudi Arabia. Part of the Jubail Phase II development is to provide 405 villas for the community. Due to the speed and efficiency in production and installation, it was decided to construct the villas using precast wall and floor panels.
Improve performance through Lean - Six Sigma managementGhinea Rodica
First steps for improving the performance of companies using Lean Six Sigma methodology, starting with manufacturing and supply chain departments (partial presentation).
Problem Statement:
Lower than expected billability, also described as Excessive Bench Capacity, results in chargeability variances and negatively impacts services margins by approximately $100,000,000 per year.
Goal Statement:
Improve billability from current 60% to 70% while maintaining planned fee adjustment. Corrective action plan will be prepared by June 200X, implemented by July 200X. Benefits will be evaluated 6 and 12 months following implementation.
The owner company is developing the Phase II of the Jubail Industrial City in Saudi Arabia. Part of the Jubail Phase II development is to provide 405 villas for the community. Due to the speed and efficiency in production and installation, it was decided to construct the villas using precast wall and floor panels.
Improve performance through Lean - Six Sigma managementGhinea Rodica
First steps for improving the performance of companies using Lean Six Sigma methodology, starting with manufacturing and supply chain departments (partial presentation).
Lean six sigma - Waste elimination (Yellow Belt)Abhay Yadav
Lean Six Sigma is a methodology that relies on a collaborative team effort to improve performance by systematically removing waste; combining lean manufacturing/lean enterprise and Six Sigma to eliminate the eight kinds of waste (muda): defects, overproduction, waiting, non-utilized talent, transportation, inventory, motion, extra-processing
Lean Six Sigma is a process improvement methodology that relies on a collaborative team effort to improve performance by systematically removing waste, combining Lean and Six Sigma to eliminate the eight kinds of waste
Lean Six Sigma projects comprise aspects of Lean's waste elimination and the Six Sigma focus on reducing defects
Six Sigma Principles And Concepts PowerPoint Presentation SlidesSlideTeam
Are you looking to take up your six sigma methodology PowerPoint show to next level? Just check out our presentation deck to thoroughly explain your six sigma approach or simply what is six sigma? By utilizing this PPT example you can motivate your employees to go for team formation so as to improve overall performance of your business processes. Additionally, with help of our PPT slideshow you can easily identify various defects and suggest measures to timely remove and maintain quality management. There is more that you can address with this PPT model like various levels of six sigma, design for six sigma, lean six sigma process improvement tools and techniques. Well bearing all this in mind, we have conceptualized creative presentation layouts like six sigma roadmap, six sigma process, the DAMIC process, voice of customer are just a few to name here. In nutshell, by downloading our six sigma principles and concepts complete PowerPoint slide deck you not only save your time, but also get best readymade PPT sample. Get your audience singing from the same sheet. Our Six Sigma Principles And Concepts Complete Powerpoint Deck With Slides can create harmony
Lean, Six Sigma, ToC using DMAIC - Measure phase Simon Misiewicz
This presentation guides you through the DMAIC methodology that encompasses Lean, Six Sigma and ToC initiatives. The Measure phase guides you through the detailed process mapping of the SIPOC diagram to Swim Lanes, spaghetti diagrams that focus on time, cost and quality. The presentation guides you though the statistics element of data sampling and to understand the theory of constraints. The presentation also discusses the use of Pareto charts to identify the key issues within a process. – Optimise-GB (Creating Operational Efficiencies)
Overview of Lean Manufacturing and Six Sigma tools, comaprison between Lean Speed and Six Sigma Quality combining Lean with Six Sigma
Overview of DMAIC and SIX SIGMA FORMULA
Six Sigma Deployement Plan: A Case StudyAyat A. Saleh
The purpose of this case study is to present a Six Sigma Deployment Plan in a company. This case study was submitted as a part of the 'Quality, Reliability and Maintenance' course in the University of Warwick, United Kingdom, 2015. For more information, you can check this blog post: https://ayatsaleh.com/2017/01/15/six-sigma-journey/
Lean six sigma - Waste elimination (Yellow Belt)Abhay Yadav
Lean Six Sigma is a methodology that relies on a collaborative team effort to improve performance by systematically removing waste; combining lean manufacturing/lean enterprise and Six Sigma to eliminate the eight kinds of waste (muda): defects, overproduction, waiting, non-utilized talent, transportation, inventory, motion, extra-processing
Lean Six Sigma is a process improvement methodology that relies on a collaborative team effort to improve performance by systematically removing waste, combining Lean and Six Sigma to eliminate the eight kinds of waste
Lean Six Sigma projects comprise aspects of Lean's waste elimination and the Six Sigma focus on reducing defects
Six Sigma Principles And Concepts PowerPoint Presentation SlidesSlideTeam
Are you looking to take up your six sigma methodology PowerPoint show to next level? Just check out our presentation deck to thoroughly explain your six sigma approach or simply what is six sigma? By utilizing this PPT example you can motivate your employees to go for team formation so as to improve overall performance of your business processes. Additionally, with help of our PPT slideshow you can easily identify various defects and suggest measures to timely remove and maintain quality management. There is more that you can address with this PPT model like various levels of six sigma, design for six sigma, lean six sigma process improvement tools and techniques. Well bearing all this in mind, we have conceptualized creative presentation layouts like six sigma roadmap, six sigma process, the DAMIC process, voice of customer are just a few to name here. In nutshell, by downloading our six sigma principles and concepts complete PowerPoint slide deck you not only save your time, but also get best readymade PPT sample. Get your audience singing from the same sheet. Our Six Sigma Principles And Concepts Complete Powerpoint Deck With Slides can create harmony
Lean, Six Sigma, ToC using DMAIC - Measure phase Simon Misiewicz
This presentation guides you through the DMAIC methodology that encompasses Lean, Six Sigma and ToC initiatives. The Measure phase guides you through the detailed process mapping of the SIPOC diagram to Swim Lanes, spaghetti diagrams that focus on time, cost and quality. The presentation guides you though the statistics element of data sampling and to understand the theory of constraints. The presentation also discusses the use of Pareto charts to identify the key issues within a process. – Optimise-GB (Creating Operational Efficiencies)
Overview of Lean Manufacturing and Six Sigma tools, comaprison between Lean Speed and Six Sigma Quality combining Lean with Six Sigma
Overview of DMAIC and SIX SIGMA FORMULA
Six Sigma Deployement Plan: A Case StudyAyat A. Saleh
The purpose of this case study is to present a Six Sigma Deployment Plan in a company. This case study was submitted as a part of the 'Quality, Reliability and Maintenance' course in the University of Warwick, United Kingdom, 2015. For more information, you can check this blog post: https://ayatsaleh.com/2017/01/15/six-sigma-journey/
Six Sigma Project Case Study Overview, from the General Electric "At the Customer, For the Customer" Six Sigma Program, led by Lean Six Sigma Master Black Belt and President of the International Standard for Lean Six Sigma (ISLSS) and Owner of the Lean Six Sigma Group
Six Sigma is a disciplined, data-driven approach and methodology for eliminating defects (driving toward six standard deviations between the mean and the nearest specification limit) in any process – from manufacturing to transactional and from product to service.
Lecture 13Application of Six Sigmain Service operati.docxsmile790243
Lecture 13
Application of
Six Sigma
in Service operations
Opportunity of Six Sigma
in Service organizationType of service organizations: Healthcare, banking, government, marketing, sales, accounting, production control, engineering, R&D etc.Service has a tremendous opportunity for Six Sigma projects.Generally, the service organizations have 30-80% waste in the processes & many activities add no value to the customers.
Example 1Type of the organization:
Software companySix Sigma project:
Improve customer order fulfillment process Six Sigma tools used
1) Statistical process control (SPC)
2) Pareto charting
3) Normal probability plotting
4) Design of Experiments (DOE)
Example 2Type of the organization:
Pharmaceutical testing companySix Sigma project:
Improve iterations of paperworkSix Sigma tools used
1) Statistical process control (SPC)
2) Pareto charting
Example 3Type of the organization:
Aerospace service companySix Sigma project:
Reduce warranty return rate after servicing products Six Sigma tools used
1) Statistical process control (SPC)
2) Pareto charting
Example 4Type of the organization:
City governmentSix Sigma project:
Evaluate the differences between city home inspectorsSix Sigma tools used
1) Sampling techniques
2) Statistical process control (SPC)
3) Pareto charting
Example 5Type of the organization:
School districtSix Sigma project:
Improve attendance in the school district Six Sigma tools used
Design of Experiments (DOE)
Example of Six Sigma project to improve
on-Time delivery
Data for late deliveries (61%)
SPC chart for current late deliveries
Pareto chart of late deliveries
Pareto chart of deliveries after improvement
SPC chart for new late deliveries
Example of Six Sigma project to increase
website traffic
Data on website “hit-rate”
SPC chart for website hit rates
Cause-and-effect matrix of website traffic
Steps to reduce the size of DOE
Review the list of factors from the cause-and-effect matrix.
Pare it down to factors that would yield insight into website traffic
Conduct a meeting of peers from all affected areas to consider expansion or deletion of selected factors (variables) for the experiments.
Group the input variables (factors) into two levels to represent the extreme of each setting.
Factors (variables) of website hit rate test
DOE test matrix
Results of implementing Six Sigma
Eight pages were created
Each page representing one of the trials listed in the DOE table
Hit rates were then collected on a weekly basis to determine which combination of factors produced the most traffic
Based on the results of the experiment, the team could determine which factors to focus on in order to increase traffic on the company website
Additional application of Six Sigma
A major appliance repair company used Six Sigma to improve its ability to return items to customers when promised.
A pharmaceutical company used Six Sigma t ...
Elimination of rework in V Cap by Using Six Sigma MethodologyIJERD Editor
The purpose of this project was to gain a strong understanding of Six Sigma management philosophy, concepts, and practices and to apply this knowledge to creating a Six Sigma academic course or training program. This was done through three main methods: preliminary research and data collection, the creation of a design model for Six Sigma academic course program establishment, and the creation of a Six Sigma academic course program syllabus. The preliminary research consisted of conducting a Six Sigma knowledge survey with the students of Worcester Polytechnic Institute, interviewing a Six Sigma expert, and examining current Six Sigma educational programs in other universities, businesses, and organizations. As a result of our observations, we determined that Six Sigma has become a large part of many companies and should be implemented into more engineering programs at universities nation-wide, including Worcester Polytechnic Institute. This can be done through a project based course, as well as more Six Sigma based Interactive and Major Qualifying Projects.
Basic overview six sigma, Six Sigma is a production philosophy that uses data, processes, and tools to nearly eliminate defects and bring performance close to perfection. Specifically, achieving Six Sigma means that no more than 3.4 defects occur per one million “opportunities” to create an acceptable output
This is complete research and study on the Six sigma and its methodology with case studies of Motorola and GE etc. This will help you a lot in understanding Six Sigma in Detail.
How to Reduce Changeover Time and Increase ThroughputOH!Manufacturing
Whether choosing iPhones, detergent bottles, industrial motors, or even bread, customers these days want more options than ever before. Marketing and product development departments recognize this and are pushing for more variety and more customization.
Root Causes Analysis for Lean Maintenance Using Six Sigma Approachtheijes
The aim of the project is to reduce rejection level of needle roller bearing assembly using six sigma techniques. Six Sigma is a quality improvement tool for product. It reduces the defects, minimizes the variation and improves the capability of the manufacturing process. The main objective of Six Sigma is to increase the profit margin, improve financial condition through minimizing the defects rate of product. Further it increases the customer satisfaction, retention and produces the best class product from the best process performance. The needle roller bearing has more Lining Thickness Variation (LTV) defect and bearing Fits like loose fit and tight fit in the production line. The current rejection level of lining thickness variation defect is very high which leads to consumption of money in the form of rework and rejection of the job. The aim of the project is to identify the causes for various assembly defect and its remedies to reduce rejection level in needle roller bearing
3. LEAN SIX SIGMA PROJECT 3
Hikma Pharma is a pharmaceutical company. Its plant is
located in 6th of October city. It produces and markets a
wide range of innovative products covering the main
therapeutic areas.
The products are classified as shown in the pie chart
below:
Analgesic
Antibiotics
Antifungals
GIT Prep.
Paediatric Prep.
Vitamins
Miscellaneous
Heart Prep.
Topical Prep.
4. LEAN SIX SIGMA PROJECT 4
There are two main blistering and packing lines in the
packaging area in Hikma plant, these lines are named Line I
and Line II.
Line II available working hours per month are 180 hours.
These hours are divided between setup, run, clean, change
over, breakdown and no schedule.
Every month the utilization of line one is calculated by using
the following formula:
(total setup + total run + total clean + total change over)
*(100/180)
7. Mission Statement:
Our company's major packaging line (CAM II) is utilized by 56.2% in the
year 2013. Increase utilization percentage in the year 2014.
Six Sigma Improvement Project Charter
Project
name
Improve machine utilization
Mission
Statement
Our company's major packaging line (CAM II) is utilized by 56.2% in the year
2013. Increase utilization percentage in the year 2014.
Team
Members
1. QA Supervisor
2. Production Supervisor
3. Production technician
4. Maintenance technician
5. QC analyst
6. Purchasing specialist
Resources
•The team is authorized to collect relevant data, discuss the problem with
those involved with it.
•Team members should have 4 hours per week available for the project.
•The team has access to the resources it needs to carry out the mission.
•Arrangements are spelled out for obtaining additional resources and policy
support if the project proves to be beyond the resources already at the
team disposal. 7
LEAN SIX SIGMA PROJECT
9. LEAN SIX SIGMA PROJECT 9
Utilization percentage of blistering line II in the year 2013:
1- Operational definitions:
•"Utilization percent": after discussion team members
agreed that utilization percent means number of hours of
run, clean, change over and setup hours divided by
theoretical hours that the machine supposed to work in
case of no defect status (180 hours).
•"Labor overtime hours": these are working hours that
are performed at non official time, e.g. in vacancies or
after official leave hours.
•"Day hours": these are the actual working hours during
day time (i.e. 8:00 – 12:00 & 12:30 - 16:30).
10. LEAN SIX SIGMA PROJECT 10
Month Utilization percent
January 56.9%
February 31.8%
March 50.7%
April 43.8%
May 87.0%
June 63.6%
July 26.3%
August 70.3%
September 54.0%
October 74.0%
November 44.4%
December 71.0%
2- Symptoms identification & measure:
•The team decided to use production monthly output report and data
posted on SAP in order to measure utilization percent per month.
•Collective data of utilization percent for each month during year 2013
was viewed, the following trend shows the results obtained.
11. LEAN SIX SIGMA PROJECT 11
Utilization percent year 2003
56.9%
31.8%
50.7%
43.8%
87.0%
63.6%
26.3%
70.3%
54.0%
74.0%
44.4%
71.0%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Month
Utilizationpercent
Utilization percent 2013
12. LEAN SIX SIGMA PROJECT 12
PLANNING
MATERIALS
AND
RESOURCES
ORDER
ISSUEING
PROCESS
ORDER
PRODUCTION
PRODUCTION
PROCESS
ORDER
MATERIALS
PREPARATION
PACKAGING
COMPONENTS
W.H
13. LEAN SIX SIGMA PROJECT 13
Issue work order
Planning
Revise work
order, check
validity
Receive work
order
Prepare needed
materials
Receive &
revise lot no.
& qty.
Machine run
and setup
FN
Product
QAProductionWHProduction
Production
Process map
14. LEAN SIX SIGMA PROJECT 14
Month Utilization percent
January 0.6
February 0.3
March 0.5
April 0.4
May 0.9
June 0.6
July 0.3
August 0.7
September 0.5
October 0.7
November 0.4
December 0.7
MIN 0.3
MAX 0.9
AVERAGE 0.6
σ 0.2
AV-3σ 0.0
AV+3σ 1.2
15. LEAN SIX SIGMA PROJECT 15
Serial
Contributors
Number of
breakdown
hours
Percentage
Cumulative
percentage
1 PVC 27.4375 20.591% 20.591%
2 Air 21.75 16.323% 36.914%
3 Carton m/c 20.9375 15.713% 52.627%
4 Sorting 16 12.008% 64.634%
5 m/c setting 13.4375 10.084% 74.719%
6 Waiting material 6.75 5.066% 79.784%
7 Aluminum 6.25 4.690% 84.475%
8 Sealing 4.1875 3.143% 87.617%
9 Blister m/c 4 3.002% 90.619%
10 Others 3.75 2.814% 93.433%
11 Maintenance 2.5 1.876% 95.310%
12 Administrative 2.5 1.876% 97.186%
13 Calibration 2.25 1.689% 98.874%
14 electricity 1.5 1.126% 100.000%
Pareto analysis was constructed to show the contributors of Break
down hours of Line II and the vital few contributors that affect Line II
breakdown
16. LEAN SIX SIGMA PROJECT 16
PVC
Air
Carton m/c
Sorting
m/c setting
Waiting material
Aluminum
Sealing
Blister m/c
Others
Maintenance
Administrative
Calibration
electricity
17. LEAN SIX SIGMA PROJECT 17
Pareto Analysis
0
20
40
60
80
100
120
PVC Air Carton m/c Sorting meshwar Waiting
material
Aluminum Sealing Blister m/c Others Maintenance Administrative Calibration electricity
Contributors
Numberofhours
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Cumulativepercentage
Vital Few
As shown from the analysis the first three contributors shared by
52.6% of the problem (i.e. Vital Few contributors).
The team suggested to concentrate on the first 2 problems – PVC &
Compressed Air – that contribute with 36.9% of the problem.
After argument we agreed to take the first two contributors in our
consideration.
19. LEAN SIX SIGMA PROJECT 19
The project sponsor suggested the segregation of compressed air
problem in a separate improvement subproject since the company will install
a new compressor after 2 months.
The team now had reached a common understanding of the process and
had known that the major factor that increases the breakdown time is
the PVC problems.
20. LEAN SIX SIGMA PROJECT 20
MONTH
PVC
Stoppage hours
UTILIZATION
JAN 2 56.90%
FEB 4 31.80%
MAR 2.5 50.70%
APR 2 43.80%
MAY 0.5 87.00%
JUN 2 63.60%
JUL 5 26.30%
AUG 1.5 70.30%
SEP 2.5 54.00%
OCT 1 74.00%
NOV 3 44.40%
DEC 1.5 71.00%
