6

Six Sigma Project

Project Number

TACL 109

Plant

TACL Faridabad

Name of the Green Belt

Lalta Prasad Gupta

Team Members

Date of Start

30.12.2009

Slide number: 1

Phase 1- Problem Definition

Problem Statement

Thickness Variation

Part number selected for study

X1707700

Other similar part numbers having the problem

NA

Last manufacturing process stage where technically the problem can get
generated
Reactivation Process

Process stages where the problem is detected

Current average rejection for last 6 months

Reactivation and Final Inspection

33.8 %

Maximum and Minimum rejection in last 6 months

Maximum rejection in a month - 45.4 %
Minimum rejection in a month - 28.2 %
Slide number: 2

Phase 1- Problem Definition

Number of lines/presses/machines used for processing

Objective of the Project

To reduce rejection from 33.8 % to 6.76 %

Annual Savings in Rs. Lakhs if the defect is made zero and horizontally
deployed to other part numbers

1 Press

0.43 Lakhs

Response
Variable

Specification (if the response is variable)

1.300.1

Is R&R study required

No

Slide number: 3

Phase 1- Problem Definition

Process Mapping
Slitting of facing
Preglueing of facing
Cropping of core
Blanking Of Core & Facing
Reactivation

Post Curing

Final Inspection

Slide number: 4

Phase 1- Problem Definition

Project Planning
Phase

Dec09
W1

W2

W3

Jan10
W4

W1

W2

W3

Feb10
W4

W1

W2

W3

W4

Define
Measure
& Analyze
Improve
Control
Phases

Planned Start
date

Planned
Completion
date

Actual start
date

Actual
completion
date

Status

Define

26.09.09

2.01.10

30.12.09

5.01.10

Completed

Measure &
Analyze

6.01.10

23.01.10

7.01.10

3.02.2010

Complete

Improve
Control

Slide number: 5

Phase 1- Problem Definition

Photograph of defect part

Top Facing A

Steel Core B

Bottom Facing C

A+B+C
Slide number: 6

Phase 1- Problem Definition

Pareto (Based on last 6 months data)

Average Rejection = 33.8 %

Slide number: 7

Phase 1- Problem Definition

COPQ (Cost of Poor Quality) Calculation
Number of pieces rejected last month
(for the part number identified for
study)

1750 Nos

Number of pieces scrapped last month

Nil

Number of pieces reworked last month

1750 Nos

Scrap cost/piece

NA

Rework cost/piece

Rs. 1.80

Total scrap cost (Rs. Lakhs) for last

month

Nil

Total rework cost(Rs. Lakhs) for last

month

0.032 Lakhs

Total Rejection cost (Rs. Lakhs) for last

month

0.032 Lakhs

Extrapolated Total rejection cost (Rs.

Lakhs) for one year

0.43 Lakhs

Slide number: 8

Phase 1- Problem Definition

SUSPECTED SOURCES OF VARIATION FOR THE
PROBLEM
Input Material
1)Facing Thickness Top.
2)Facing Thickness Bottom.
3)Core Thickness.
4)Flattening Process.

Slide number: 9

FF

VS

OBSER

MVA

CC

CS

PPS

PC

SSVs

MCS

Phase 1- Problem Definition

FACING THICKNESS TOP

FACING THICKNESS BOTTOM
CORE THICKNESS
FALTTENING PROCESS

Legend: PC Paired Comparison, PPS Product/Process search, CS Component Search, MCS Modified Component Search, CC Concentration chart
MVA Multi-Vari analysis, OBSER Observation, VS Variable Search, FF Full Factorial
Slide number: 10

Phase 2- Measure and Analyze

Shainin DOE tool Selection
Data Collection
Analysis of Data
Conclusion based in data
Validation of the cause before
improvement

Slide number: 11

Phase 2- Measure and Analyze

Objective: Are Identified SSVS the cause for the
problem

Technique/Tool used: Product Process Search

Slide number: 12

Phase 2- Measure and Analyze

DATA FOR HINO OIL COOLER X1707700
Facing
Thick.Glue
Sr. No. Up

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

0.622
0.63
0.633
0.613
0.604
0.625
0.616
0.618
0.645
0.606
0.603
0.605
0.61
0.62
0.625
0.615
0.627
0.597
0.602
0.607
0.604
0.623
0.628
0.633
0.618

Core
Thick.

0.283
0.284
0.283
0.285
0.28
0.284
0.283
0.287
0.284
0.282
0.285
0.287
0.29
0.285
0.285
0.287
0.284
0.283
0.288
0.284
0.285
0.287
0.285
0.285
0.284

Facing
Thick. Glue Reactivation
down
Thick.

0.621
0.628
0.625
0.635
0.587
0.623
0.625
0.637
0.607
0.593
0.625
0.623
0.621
0.61
0.607
0.613
0.624
0.617
0.627
0.625
0.624
0.641
0.63
0.605
0.632

1.396
1.42
1.42
1.41
1.372
1.41
1.41
1.42
1.416
1.378
1.4
1.42
1.414
1.42
1.416
1.42
1.41
1.4
1.39
1.402
1.412
1.44
1.406
1.41
1.402

Sr. No.

26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50

Facing
Thick.Glue Core
Up
Thick.

0.625
0.607
0.613
0.609
0.615
0.606
0.625
0.615
0.624
0.608
0.605
0.624
0.613
0.627
0.61
0.593
0.6
0.612
0.616
0.62
0.631
0.622
0.59
0.593
0.59

0.285
0.287
0.289
0.286
0.288
0.288
0.288
0.284
0.285
0.286
0.286
0.284
0.286
0.287
0.285
0.284
0.285
0.286
0.287
0.281
0.288
0.285
0.283
0.283
0.286

Facing
Thick.
Reactivation
Glue down Thick.

0.621
0.618
0.617
0.6
0.603
0.593
0.614
0.615
0.615
0.623
0.643
0.618
0.634
0.625
0.646
0.645
0.637
0.586
0.614
0.633
0.603
0.635
0.625
0.634
0.634

1.4
1.392
1.424
1.414
1.42
1.402
1.41
1.396
1.4
1.404
1.42
1.42
1.426
1.424
1.42
1.408
1.448
1.416
1.436
1.45
1.44
1.43
1.418
1.416
1.424
Slide number: 13

Phase 2- Measure and Analyze

Sr. No.
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75

Facing
Thick.Glu Core
e Up
Thick.
0.593
0.287
0.624
0.288
0.603
0.283
0.602
0.284
0.594
0.284
0.628
0.285
0.61
0.286
0.617
0.288
0.608
0.283
0.625
0.284
0.593
0.283
0.587
0.284
0.613
0.287
0.598
0.288
0.593
0.287
0.624
0.283
0.616
0.284
0.617
0.284
0.621
0.288
0.617
0.287
0.58
0.285
0.608
0.286
0.595
0.283
0.597
0.286
0.623
0.286

DATA FOR HINO OIL COOLER X1707700

Facing
Facing
Thick.
Reactivati
Thick.Glu Core
Glue
on Thick. Sr. No.
e Up
Thick.
0.597
1.41
76
0.637
0.284
0.606
1.4
77
0.625
0.285
0.6
1.383
78
0.614
0.284
0.614
1.392
79
0.637
0.287
0.608
1.37
80
0.624
0.287
0.605
1.4
81
0.607
0.283
0.614
1.386
82
0.593
0.28
0.583
1.39
83
0.577
0.285
0.614
1.38
84
0.593
0.285
0.605
1.4
85
0.596
0.283
0.614
1.384
86
0.614
0.288
0.594
1.396
87
0.613
0.287
0.615
1.4
88
0.614
0.287
0.63
1.398
89
0.605
0.285
0.607
1.374
90
0.604
0.289
0.61
1.404
91
0.626
0.283
0.605
1.4
92
0.607
0.286
0.625
1.42
93
0.603
0.288
0.634
1.428
94
0.604
0.287
0.63
1.43
95
0.595
0.285
0.635
1.384
96
0.6
0.284
0.626
1.400
97
0.578
0.284
0.625
1.378
98
0.625
0.284
0.61
1.396
99
0.626
0.283
0.598
1.400
100
0.6
0.282

Facing
Thick.
Glue
0.605
0.627
0.644
0.598
0.6
0.615
0.595
0.605
0.594
0.603
0.608
0.625
0.625
0.614
0.61
0.645
0.624
0.634
0.62
0.616
0.615
0.61
0.625
0.63
0.635

Reactivati
on Thick.
1.430
1.412
1.416
1.392
1.404
1.39
1.39
1.385
1.4
1.388
1.4
1.384
1.4
1.382
1.404
1.4
1.407
1.382
1.385
1.358
1.378
1.363
1.41
1.4
1.415
Slide number: 14

Phase 2- Measure and Analyze

CALCULATION OF COUNT FOR BOTTOM FACING THICKNESS
Sr. No.
76
46
22
69
45
70
44
10
5
42
96
73
95
55
65
97

BOTTOM
FACING
0.637
0.631
0.623
0.621
0.62
0.617
0.616
0.606
0.604
0.6
0.6
0.595
0.595
0.594
0.593
0.578

TOP COUNT= 7
STATUS
WOW7
WOW3
WOW4
WOW8
WOW1
WOW6
WOW5
BOB 8
BOB4
WOW2
BOB 6
BOB 7
BOB 1
BOB 3
BOB 5
BOB 2

BOTTOM COUNT=5.5
TOTAL COUNT =12.5

New Spec = 0.475-0.595mm

Variation in FACING = 0.068
Derived Tolerance = 0.12
Ratio
=(0.068/0.12)*100
= 56.7 %
So less than 75% of tolerance
so can be controlled.
Hence its a root cause

Slide number: 15

Phase 2- Measure and Analyze

CALCULATION OF COUNT FOR CORE THICKNESS
Sr. No.
46
69
65
22
44
70
95
42
55
96
97
76
73
10
45
5

Core
Thick.
0.288
0.288
0.287
0.287
0.287
0.287
0.285
0.285
0.284
0.284
0.284
0.284
0.283
0.282
0.281
0.28

TOP COUNT= 2
STATUS
WOW3
WOW8
BOB 5
WOW4
WOW5
WOW6
BOB 1
WOW2
BOB 3
BOB 6
BOB 2
WOW7
BOB 7
BOB 8
WOW1
BOB4

BOTTOM COUNT=1
TOTAL COUNT =3

As count is less than 6

so it is not a cause

Slide number: 16

Phase 2- Measure and Analyze

CALCULATION OF COUNT FOR TOP FACING THICKNESS
Sr. No.
22
42
69
45
70
73
95
96
44
97
55
65
76
46
10
5

TOP
FACING
0.641
0.637
0.634
0.633
0.63
0.625
0.616
0.615
0.614
0.61
0.608
0.607
0.605
0.603
0.593
0.587

STATUS
WOW4
WOW2
WOW8
WOW1
WOW6
BOB 7
BOB 1
BOB 6
WOW5
BOB 2
BOB 3
BOB 5
WOW7
WOW3
BOB 8
BOB4

TOP COUNT= 5
BOTTOM COUNT=2
TOTAL COUNT =7

New Spec = 0.473-0.593mm

Variation in FACING = 0.062
Derived Tolerance = 0.12
Ratio
=(0.062/0.12)*100
= 51.7%
So less than 75% of tolerance
so can be controlled.
Hence its a root cause

Slide number: 17

Phase 2- Measure and Analyze

Conclusion(s): Top Facing Thickness and

Bottom Facing Thickness are Roots Causes
Identified.

Slide number: 18

Phase 2- Measure and Analyze

Total Analysis summary

Cause(s) identified for the problem: Top Facing

Thickness And Bottom Facing Thickness Are Causes
Identified

Root cause(s) identified for the problem: Top Facing

Thickness and Bottom Facing Thickness

Slide number: 19

Phase 2- Measure and Analyze

Validation Of Root Cause Before Improvement

Sr. No.
17
18
11
16
12
20
13
15
7
2
4
8
10
9
5
1

Bottom
Reactivation
Facing
Thick.
0.614
1.438
0.614
1.434
0.626
1.432
0.624
1.43
0.62
1.426
0.62
1.424
0.626
1.418
0.62
1.418
0.564
1.362
0.58
1.36
0.574
1.354
0.568
1.354
0.578
1.354
0.57
1.35
0.582
1.346
0.57
1.338

Count is 16 so root cause is

validated for derived spec.

Slide number: 20

Phase 2- Measure and Analyze

Validation Of Root Cause Before Improvement
Sr. No.
17
18
11
16
12
20
13
15
7
2
4
8
10
9
5
1

Top
Reactivati
Facing
on Thick.
0.632
1.438
0.634
1.434
0.63
1.432
0.62
1.43
0.622
1.426
0.63
1.424
0.63
1.418
0.618
1.418
0.584
1.362
0.59
1.36
0.576
1.354
0.59
1.354
0.58
1.354
0.576
1.35
0.58
1.346
0.584
1.338

Count is 16 so root cause is

validated for derived spec.

Slide number: 21

Phase 2- Measure and Analyze

Conclusion
As Top Facing And Bottom Facing Shares same
specification in drawing so a common
specification is concluded for both the facings.

Specification:- 0.530.06
That can accommodate calculated spec.
0.475~0.595

Slide number: 22

Phase 3 - Improve
Validation of the Root cause(s)- B Vs C
1

Part number selected

for validation

Better Condition
Current Condition

Sample size

6B,6C / 3B,3C

Sample type

Pieces / Lots

Response decided for

monitoring

Historic rejection

Lot quantity

Is alternating between Yes / No

B and C condition
possible

Slide number: 23

Phase 3 - Improve
Validation of the Root cause(s)- B Vs C
Piece / Lot

Better ( B )

Current ( C )

1
2
3
4
5
6

Slide number: 24

Phase 3 - Improve
Data

Slide number: 25

Phase 3- Improvement
Analysis - B Vs C
1

Part number selected

for validation

Average of B
Average of C

Total count

Xb Xc (Amount of
Improvement)

Sigma (B)

Is Xb-Xc greater than

Sigma (b)

Confidence level of
improvement

Number of iterations
done
Slide number: 26

Phase 3 Improve Actions Summary

No

Root cause(s)

Actions Planned

Planned
Completion date

Resp

Actual
completion
date

Status

Slide number: 27

Phase 3 Improve
Photograph of actions

Slide number: 28

Phase 3 Improve
Photograph of actions

Slide number: 29

Phase 3 Improve
Photograph of actions

Slide number: 30

Phase 4 Control Phase

No

Root cause

Variation
analysis done

Type of control
method decided

Status of implementation

Slide number: 31

Phase 4- Control
Analysis # 1
Objective:
Tool/technique used:
-

Slide number: 32

Phase 4- Control
Steps in Variation analysis
Step 1 : Identify the Parameter that requires Variation analysis
Parameter :

Step 2 : Identify are there multiple Product and Process streams

Number of streams :
Type of streams
:

Slide number: 33

Phase 4- Control

Slide number: 34

Phase 4- Control
Data

Slide number: 35

Phase 4- Control
Data

Slide number: 36

Phase 4- Control
Multi Vari analysis - Conclusion
Part to Part variation
Time to Time variation
Stream to Stream variation -

Slide number: 37

PHASE - 4

CONTROL PHASE

Step: 7 Check the consistency of the part to Part variation

Paste your range chart here

Slide number: 38

PHASE - 4

CONTROL PHASE

Slide number: 39

PHASE - 4

CONTROL PHASE

Estimated part to part variation at 99.73%

confidence level is :

Slide number: 40

PHASE - 4

CONTROL PHASE

Slide number: 41

PHASE - 4

CONTROL PHASE

Slide number: 42

PHASE - 4

CONTROL PHASE

Slide number: 43

Phase 4- Control
Analysis # 1
Objective:
Conclusion:
-

Slide number: 44

Phase 4 - Control
Results

Before

After

Slide number: 45

Phase 4- Control
Project Summary
Number of drill downs (funneling) done to reach the root
cause(s):
Number of predominant root cause(s) identified:
Time in months for completing the project:
Tools/Techniques used:

Slide number: 46

Phase 4 - Control
Benefits derived through the project
1.

Overall scrap reduced from 1.95% to 1.02%.

2.

Crack scrap reduced from 0.62% to 0.02%.

3.

Cycle time reduced from 460 seconds to 422 seconds.

4.

Estimated cost benefits is Rs. 2,18,996 per year.

Slide number: 47

Phase 4 - Control
Current control plan

Slide number: 48

Phase 4 - Control
Proposed Control plan

Slide number: 49