Car servicing

SIPOC supplier Input

customer/ driver car
service station team Job order
servicing team update the job order/ lub oil/
washing team car/ washing materials
billing team update the job order
driver invoice/ money

Exercise
1 Bank account opening

Flow chart/ swim lane

Terminator( start/end) activity box

Pizza delivery

customer gives customer information

start order
customer facing dept

kitchen prepre dough apply sauce

kitchen dept
 kitchen prepre dough apply sauce

packing customer transport

information
logistic

VSM
 Process Output customer
car comes to the station job order service station team
issues identification update the job order servicing team
car servicing serviced car/ update the job order washing team
car washing cleaned car/ update the job order billing team
billing invoice driver
car goes out of the station car, bill owner

decision box document

stomer information placed the order Conformation

no

ply sauce bake

bake proper or
not
ply sauce bake
bake proper or
not

no

transport cutomer/ payment

ends
tation team

Arrow

yes

kitchen

per or cut
per or cut

yes
LSL LCL UCL USL

-3sigma +3sigma

vop
voc

Cp VOC/VOP VOP

(USL-LSL)/6 sigma

Cp > 1 Capable
= 1 Just capable
< 1 Not capable
(Mean+3sigma)-(Mean-3 sigma)

6 sigma
 LCL LSL USL
UCL

5.65 5.8 6.4 7 7.15

Data Is normal
Sample 100
Mean 6.4
SD 0.25
Customer 6.4+/- .6

5.65 7.15

Cp= VOC/VOP

Customer 6.4+/- .6 6.4 0.6

USL 7
LSL 5.8

UCL 7.15
LCL 5.65

Cp = VOC/VOP
 =
= (USL-LSL)/6sd 3sd-(-3sd)

0.8
Cp <1 0.8 Not capable
Cp =1 just capable
Cp >1 capable
 UCL USL
LCL LSL

7 8 10 13 16

sample 100
Mean 10
SD 1
customer 12+/-4

customer 12+/-4

USL 16
LSL 8
UCL 13
LCL 7

Cp = 1.333333
 4

Cpk = (USL-MEAN)/(S.D) Z upper

(MEAN-LSL)/(S.D) Z lower

6 Z upper
2 Z lower

Cpk 0.666667
Current Sigma level 2
USL 182
LSL 160

Process Mean 178.6

SD 3.6

Cp 1.018519 3.055556

Cp upper (USL-mean)/sd

0.944444

Cp Lower (Mean-LSL)/SD

5.166667

Cpk 0.314815

Current Sigma level 0.944444

RTY Rejections 10

100
Process 1 Process 2

90

Repair and Rework 10 10

80

FTY FTY
Efficiency 0.9 0.888889

Effectiveness/RTY 0.8 0.777778

10 10

Process3
90
100
0.9

80 70 0.7

80
10 100
0.8

70 60 0.466667

FTY 0.233333
0.875 0.7 70.0

0.75 0.47 46.7

 80 70
90 80
0.888889 0.875

70 60
90 80
0.777778 0.75
Fish Bone Diagram
eg: Pizza delivery time is longer

1.Productivity
Man/People 2.skills
3.Lack of Motivation
4. Absenteeism

1.Baking machine
Machine 2.Bikes getting frequent
repaired
3.Mixing machine
Material 1.Quality of dough

1.Not informing at right

time
Method 2.Inaccurate resource
planning
3.Doing sequencial
activities

Measurement 1.Time and

temperature for baking

Raining heavily
Motherearth Enviromental factors
AAA Ram Ravi Shyam
Round1 Round 2 Round1 Round 2 Round1
1P P P P P
2F F F P P
3P P P F P
4F P F F P
5F F P P P
6F F P P P
7P F F F P

30
Round 2 Master Calibration
P P
P F
P F
P P
P P
P F
P P
 TPS
Muda Muri Mura

Principles Tool

1 Identify Value TIMWOODS

2 Mapping the Value stream VSM
3 Create flow
4 Establish Pull JIT PULL KANBAN

Suppliers raw materials process1 process2 process3

2 2 2 2 2

5 Seek perfection Kaizen

kanban
Poka Yoke
5S
 T Transportation
I Inventory
M Motion
W waiting time
O Overprocessing
O Overproducig
D Defects
testing showroom customer S skills
1 2
1
2 1
1
VSM
High Level
Customer requirement

welding grinding

NVA 45

CT 10 30

Current PCE 65% VA/(VA+NVA)

8 hrs shift

Customer demand 100 Units

Takt Time 4.8 mins/unit

 Customer get product

grinding Drilling/milling finishing

45 50 140

30 180 45 265

405
get product

TNVA

TCT(VA)

Lead Time(LT)
 Pay off matrix
From SME Benefits(H/L) Efforts(H/L)
Sol 1 L H
Sol 2 H L high
Sol 3 H L
Sol 4 H L Benefit
Sol 5 L H
Sol 6 L H
Sol 7 L H
Sol 8 H H low
Sol 9 H L
Sol 10 H L
Sol 11 L L
Sol 12 H H

NGT 1-6 Total Score

Solution P1 P2 P3 Add
s1 6 5 4 15
s2 4 6 5 15
s3 5 4 6 15
s4 3 3 3 9
s5 2 1 2 5
s6 1 2 1 4

N/3 Voting
Solution P1 P2 P3 Total
sol1 1 1 1 3
sol2 1 1
sol3 0
sol4 1 1 2
sol5 1 1 2
sol6 1 1
sol7 0
sol8 0
sol9 1 1 2
 sol10 0
sol11 1 1
sol12 0

1/5/9( L/M/H)
CBM Criteria Wt sol1(# of votes) sol2 sol3
Quality 9 0 1 3
Compliance 9 7 2 4
cost effective 5 5 3 5
reduce time 5 7 4 7
easy for ppl to use 1 2 6 8
TOTAL SCORE 125 68 131
 sol3, sol2, sol4 sol8, sol 12
CBA

Sol11 sol1,sol5, sol6, sol7

low high
Effort

Total Score
sol4 sol5
5
6
4
3
6
FMEA

causes of
severity failure
Process Failure mode Failure effect nos(1-10) mode occurance(1-10)
step 10 1
7 2
5
6
8
9
10
current control Recomended
system detection(1-10) RPN action
10 100