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    Example GB - Assignment 2 - Lean Six Sigma Green Belt-3

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    mrshojaee
    The document describes a nasal spray bottle packaging process and identifies areas for improvement using Lean Six Sigma tools. It details the process flow, inputs, outputs, suppliers, and customers. A CTQ tree is created to identify critical quality attributes and 5 pain points are determined through a cause-and-effect diagram to focus improvement efforts.

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    © All Rights Reserved
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    Example GB - Assignment 2 - Lean Six Sigma Green Belt-3

    Uploaded by

    mrshojaee
    46 views10 pages
    The document describes a nasal spray bottle packaging process and identifies areas for improvement using Lean Six Sigma tools. It details the process flow, inputs, outputs, suppliers, and customers. A CTQ tree is created to identify critical quality attributes and 5 pain points are determined through a cause-and-effect diagram to focus improvement efforts.

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    Example GB _Assignment 2_Lean Six Sigma Green Belt-3

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    The document describes a nasal spray bottle packaging process and identifies areas for improvement using Lean Six Sigma tools. It details the process flow, inputs, outputs, suppliers, and customers. A CTQ tree is created to identify critical quality attributes and 5 pain points are determined through a cause-and-effect diagram to focus improvement efforts.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    46 views10 pages

    Example GB - Assignment 2 - Lean Six Sigma Green Belt-3

    Uploaded by

    mrshojaee
    The document describes a nasal spray bottle packaging process and identifies areas for improvement using Lean Six Sigma tools. It details the process flow, inputs, outputs, suppliers, and customers. A CTQ tree is created to identify critical quality attributes and 5 pain points are determined through a cause-and-effect diagram to focus improvement efforts.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 10

    Lean Six Sigma

    3867 Lean Six Sigma Green Belt Online

    Assignment #2
    Student # :

    Name :
    Lean Six Sigma

    Part 1
    Lean Six Sigma

    Process Description D M A I C

    ▪ The process described in this presentation is the packaging of filled nasal spray bottles used for treating
    nasal allergies.
    ▪ Packaging of a nasal spray bottle includes packaging components such as labels, individual cartons, and a
    shipper box. And in addition, an automated inspection process is integrated to the critical stations to ensure
    each and every bottle processed meets specifications.
    ▪ At the end of the process, where the shipper level packaging takes place, a serialization process occurs for
    product traceability after which the completed shipper boxes are stacked into a skid and then shipped to the
    warehouse.
    Lean Six Sigma

    Process Description (cont’d) D M A I C

    ▪ The process prior to the packaging is called the filling process which is also the supplier of the filled bottles.
    This operation is responsible for processing the bulk compound of the nasal spray and dispenses it to the
    individual bottles.
    ▪ On the line are trained operators who operates the equipment and performs tasks to successfully process the
    inputs into outputs. Quality technicians performs inspections at predetermined intervals to capture and
    ensure that the products produced is adhering to the specifications. Mechanics ensure that the equipment is
    running smoothly and performing as intended and also troubleshoots equipment issues on the line.
    ▪ The KPI’s for the packaging process is the ability to process each and every bottle efficiently and without
    defect or rework, meet or exceed target cycle time, eliminating non-value-added tasks while improving the
    value-added ones, all while maintaining quality standards.
    Lean Six Sigma

    SIPOC D M A I C
    Lean Six Sigma

    CTQ Tree D M A I C

    ▪ The primary needs directly adhere to the KPI of the process.

    Secondary Need Third Level Need Fourth Level Need


    Primary Need CTQ/ Divers CTQ / Drivers CTQ / Drivers
    Fixed housing on cameras and
    Determine best camera
    modular height adjustment
    position and angle
    Optimal camera positions instead of individual
    Document focus and aperture
    Determine focus and aperture
    1. Accurate inspection of crimp based DOE results
    on bottles Include creating of new
    Up-to-date reference image of Create reference image every
    reference image every set-up
    crimp for inspection set-up
    on procedures
    Synchronize speed of conveyor +/- 0.2 seconds allowable speed
    for both filling and packaging difference
    Better adhesive remover for
    < 10 mins of soak time
    labels
    Increased routine maintenance Availability of spare parts and
    Bi-monthly
    2. Reduction of WIP on Labeller on critical parts man power resource
    Filling to stop as soon as
    packaging stops or if turn table
    is full
    less smudging and resistant to
    Better print head capability
    3. Reduction of cartoner dust particles
    defects Increased routine maintenance Availability of spare parts and
    Bi-monthly
    on critical parts man power resource
    Lean Six Sigma

    Cause and Effect D M A I C

    5 Pain Points
    ❑ Camera position
    ❑ Filling conveyor does
    not stop when
    packaging side stops
    ❑ Reference image on
    the crimp is not up to
    date with what is
    currently running
    ❑ Undefined method of
    manual inspection
    ❑ Correct set-up of
    inspection system
    Lean Six Sigma

    5 Why Analysis D M A I C
    Lean Six Sigma

    A3 Report D M A I C
    Lean Six Sigma

    Part 2

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