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    Lesson - 5.5 - Project 01 - Improve Phase - Forklift Pocess (Contd.)

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    طلال المطيري
    Through analysis, the project team identified inconsistencies in vendor and company serial number definitions and a manual input process as contributing to defects. Potential improvements included standardizing serial numbers, eliminating data lags, creating expired forklift reports, and auditing/payment changes for non-matching forklifts. After implementing solutions, the defect rate dropped, improving process sigma from 2.146 to 3.035.

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    Lesson - 5.5 - Project 01 - Improve Phase - Forklift Pocess (Contd.)

    Uploaded by

    طلال المطيري
    28 views9 pages
    Through analysis, the project team identified inconsistencies in vendor and company serial number definitions and a manual input process as contributing to defects. Potential improvements included standardizing serial numbers, eliminating data lags, creating expired forklift reports, and auditing/payment changes for non-matching forklifts. After implementing solutions, the defect rate dropped, improving process sigma from 2.146 to 3.035.

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    PPT_Lesson_5.5_Project 01_Improve Phase_Forklift Pocess(contd.)

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    Through analysis, the project team identified inconsistencies in vendor and company serial number definitions and a manual input process as contributing to defects. Potential improvements included standardizing serial numbers, eliminating data lags, creating expired forklift reports, and auditing/payment changes for non-matching forklifts. After implementing solutions, the defect rate dropped, improving process sigma from 2.146 to 3.035.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    28 views9 pages

    Lesson - 5.5 - Project 01 - Improve Phase - Forklift Pocess (Contd.)

    Uploaded by

    طلال المطيري
    Through analysis, the project team identified inconsistencies in vendor and company serial number definitions and a manual input process as contributing to defects. Potential improvements included standardizing serial numbers, eliminating data lags, creating expired forklift reports, and auditing/payment changes for non-matching forklifts. After implementing solutions, the defect rate dropped, improving process sigma from 2.146 to 3.035.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 9

    Lean Six Sigma Green Belt

    Certification Course
    Project: Improve Phase
    Improve Phase

    This case study is a project simulation. As we complete each Phase of the DMAIC (Define, Measure,
    Analyze, Improve, and Control) process, different aspects of the case study will be presented to you. You
    will be given background information, instructions, data sets, project updates, and all necessary
    information to work through each step of the project and answer questions.

    Note:
    You will be using only some of the DMAIC tools and techniques in the case study to practice solving a
    single problem.
    The provided solutions are not the “perfect” answers; they are only one of many potential solutions.
    Project Update: Outcome Summary

    Through hypothesis testing and additional analysis, the project team was able to identify the source of the
    defects in the forklift fulfillment process. The significant contributors identified to the problem were:
    • Vendor had inconsistent definition of serial number
    • Your company had inconsistent definition of serial number
    • Input process is manual
    • Lag in receiving data
    Project Update

    Quick Wins and Mistake Proofing

    The team is ready to develop a strategy to improve. Some simple process changes could have a significant
    impact on the process performance.
    Project Update

    Potential Improvements
    The team came up with a list of potential improvements to the forklift fulfillment process that could
    facilitate accurate forklift tracking. The team worked with vendors to ensure that each forklift had a
    unique serial number or identifier. Other improvements include:
    • The elimination of time lag between vendors’ records and the company records
    • Creating a monthly expired forklift report to flag forklifts that the company is still being charged for
    although the lease has expired
    • Implementing an audit process to find forklifts with non-matching serial numbers
    • Changing the SOP to short-pay invoices for non-matching or expired forklifts
    Project Update

    Verify Improvements
    A key component of the Improve phase is the ability of the team to verify improvement success. After
    solutions are implemented for several weeks, your team collects data from the latest report. There were
    5001 invoices and a total of 312 defects based on the team’s defect definition.
    Improve Phase Questions

    1. What should be the outcomes of the Improve phase?


    2. Based on the team’s findings in the Analyze phase, what ideas for quick hit improvements or poke-
    yoke can the team come up with?
    3. What type of graphical summaries can the team create to display the improvement impact?
    4. What is the process sigma level on the new project data?
    5. How does the new process performance compare to the baseline performance?
    Improve Phase Answers

    1. The Improve phase should result in implemented solutions that have effectively improved performance.
    2. A couple of quick wins include process automation and a more standardized serial number creation
    system.
    3. To show process improvements in a graphical display, Control Charts, Trend Charts, and Box and
    Whiskers Plots could be used.
    4. See improved Sigma Level calculation in the table below.
    5. The new process Sigma Level of 3.035 shows an improvement from the previous 2.146 Sigma Level.

    Step Equation Result


    Determine number of defect opportunities per
    unit O= 1
    Determine number of units processed N= 5001
    Determine total number of defects made D= 312
    0.0623875
    Calculate defects per opportunity DPO = D / (N X O)= 2
    Calculate yield Yield = (1-DPO)*100 93.76
    Sigma Level from Sigma conversion table process sigma = 3.035

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