DMAIC

Project Name : Cycle time reduction.

Project Owner : s.n. parmar,ajay kumar choudhari

1 10/15/2022
 Project Progress Overview Overview

Define Measure Analyze Improve Control

Tollgates:
Planned 03/may/2013 18may/2013 18/d05/2013 27/05/2013 05/06/2013
Completed XXXXXX 15/March/2010 mm/dd/yyyy mm/dd/yyyy mm/dd/yyyy
M1. CTQ Characteristics& A1. Baseline Process I1. Screen for Vital Xs C1. MSA on Xs
Steps: D1. Map Project
D2. Approve Project Standards A2. Performance I2. Screen for vital Xs C2. Improved Process Capability
M2. Measurement System Objective I3. Define Improved C3. Establish Control Plan
Analysis A3. Identify Drivers of Process
M3. Data Collection Variation

Key Deliverables:
• List of Customer(s) and • QFD / CTQ Tree • Baseline of Current • List of Vital Few Xs • MSA Results on Xs
Project CTQs • Operational definition, Process Performance • Transfer Function(s) • Post Improvement
• Team Charter Specification limits, • Normality Test • Optimal Settings for Capability
• High Level Process Map target, defect definition • Statistical Goal Xs • Statistical Confirmation
(COPIS) for Project Y(s) Statement for Project • Confirmation of Improvements
• CAP Plan (Optional) • Data Collection Plan • List of Statistically Runs/Results • Process Control Plan
• Preliminary CBA, if • Measurement System Significant Xs • Tolerances on Vital • Process Owner Signoff
applicable Analysis Few Xs • Final CBA, if applicable

Tools:  Survey  Data Collection Plan  Basic Statistics  DOE  Continuous Gauge R&R
 Focus Groups  Continuous Gage R&R  Histogram  Pugh Matrix  Discrete Gauge R&R
 Interviews  Attribute Gage R&R  Dot Plots  New Process Mapping  Control Charts
 ARMI, Stakeholder  Sample Size Calculator  Box and Whisker Plots  FMEA on new process  Hypothesis Testing
Analysis  Other ______________  Run Charts  Process Modeling /  CAP Plan
 In/Out of Frame  Normality Testing Simulation  Control Plan
 Threat vs. Opportunity  Continuous/Discrete Zst, Zlt  Other ______________  Other ______________
Matrix  Benchmarking
 Other ______________  Detailed Process Mapping
 Moments of Truth
 Nature of Work
 Flow of Work
 Fishbone
 Hypothesis Testing
 Regression Analysis
 Other ______________

2 10/15/2022
 Define

1. Blank
2. Project Charter
3. Terms and Acronyms Used
4. ARMI & Communication Plan/Why not RASIC
5. SIPOC
6. Process Map

3 10/15/2022
 Define

Key Output Characteristics

Customer Sample Comments
Important to Customer (CTQ's)

Maheh kumar we are facing our CD manufacturing cycle time Reduce cycle time .

(CEO) is very high 405 second Instead of 300 second

ABC Ltd. so we are not achieving Production on time.

Ajay Kumar choudhari Customer not received product on time . Reduce cycle time.

General manager

ABC Ltd.

Customer

4 10/15/2022
 Project Charter Define

Business Case:ABC Ltd. is the largest optical In Scope:Quality control.

media manufacturer in the world. We are also
manufacturer photo voltaic cell. We make CD
/DVD at automation line from raw material
(polycarbonate) to final disc in which use of
polycarbonate, dye, ml, bonding glue ,silver etc. Out of Scope:All the other process of this
First time raw material (polycarbonate ) feeding organization.
in moulding m/c after we receive blank substrate .
disc than disc going for dye coating than coated
disc go to dryer for 30 minutes at 90 degree
farnhite temp. after than silver coating on the High Level Project Plan
disc for reflectivity . And take one blank Milesto Target Date Actual Date
substrate disc bonding on dye coated disc. ne
Start Xxxx
Problem Statement: Last two months data show Date
that average cycle time 405 second instead of D 03/05/2013
300 second which is 53% productivity loss from
our target and its effect on our customer and M 10/05/2013
profit. . A 18/05/2013
I 27/05/2013
Goal Statement: I will be reduc the cycle time 405
C 05/06/2013
to 300 second on dated 15 th june 2013.

5 10/15/2022
 Terms and Acronyms Used Define

Definitions:

Indicators Definition

6 10/15/2022
 ARMI & Communication Plan Define
ARMI Worksheet
Key Stakeholders Define Measure Analyze Improve Control
Stakeholders-CEO
I I I I I
Sponsor-VP
A A I A A
Hod of production
I i I I I
Quality head
I R I I I
BB
I A M/A M M
Team Members
I R R I I

Communication Plan
Message Audience Media Who When
Project Status
Leadership E Mail BB Weekily
Tollgate Review VP,BB,HOD PROD.,HOD E mail conference calls
BB As per project plan
QUALITY, meetings
Project Deliverables or E mail conference calls
Activities
MEMBERS meetings BB/MEMBER WEEKILY

When Populating the Stakeholder, consider the ARMI:

• A= Approver of team decisions
• R= Resource or subject matter expert (ad hoc)
• M= Member of team
• I= Interested Party who will need to be kept
informed
7 10/15/2022
 SIPOC Define

SUPPLIER INPUT PROCESS OUTPUT CUSTOMER

ABC Ltd. Werehouse Raw material (PC) production production

ABC Ltd. Moulding machine Moulding (make production production

blank substract)

ABC Ltd. Dye lab Dye coating on blank production production

substract

ABC Ltd. Disc dryer Dry the disc in the production production
dryer

ABC Ltd. sputter Silver coating on the production production

disc

ABC Ltd. Store/bonding One substract disc production production

material bond on the dye
coated disc.

ABC Ltd. scanner Final scanning. At production production

scanner

ABC Ltd. production Finished disc production Quality

8 10/15/2022
 Measure

1. Data Collection Plan

2. Measurement System Analysis
3. Process Capability

9 10/15/2022
 Data Collection Plan Measure

Y Operational Defect Performance Specification Opportunity

Definition Definition Standard Limit

To reduce Disc cycle time More then 300 300 sec. Usl (300 sec.) weekly
cycle time. should not be c/s per disc.
more than 300
seconds.

Mode of collecting Data

Existing or If New when

Data Base new data data base Plan start
Container date for DCP
Y Data Type Unit Decimal to base would be
be Used ready.
To reduce continuous seconds 2 Excel Two month yes 03/05/13
cycle time old data

Formula Data Equipment Equipment

Used for Responsibilit Any Training Operator
to be items measuremen Calibration y need Information
Information
used needed t

Total Cycle time Timer clock BB yes

production weekly Mr. mahant
/total time.

10 10/15/2022
 Measurement System Analysis Measure
Minitab Descriptive Stats

Gage R&R
Rule Rule Description Acceptable Result
%Contribution
Source VarComp (of VarComp)
Total Gage R&R 0.2 0.00
Repeatability 0.2 0.00 R&R % of
A 0.25% ok
Reproducibility 0.0 0.00 Tolerance
oper 0.0 0.00
Part-To-Part 25932.1 100.00
Total Variation 25932.3 100.00

Process tolerance = 1 % Contribution

B (R&R Std 0 ok
Study Var %Study Var deviation)
%Tolerance
Source StdDev (SD) (6 * SD) (%SV)
(SV/Toler)
Total Gage R&R 0.410 2.458 0.25
245.79
Repeatability 0.410 2.458 0.25 Number of distinct
C 554 ok
245.79 categories
Reproducibility 0.000 0.000 0.00
0.00
oper 0.000 0.000 0.00 0.00
Part-To-Part 161.035 966.208 100.00 Ok
96620.76 Overall Gage result
Total Variation 161.035 966.211 100.00
96621.07

11 10/15/2022
Measurement System Analysis
Measure

12 10/15/2022
 Process Capability Measure

since P value <0.05

hence it significant
effect on
population.

Data is not normal so that the process

Capability is not require so DPMO calculate.

13 10/15/2022
 Measure

DPMO Dpmo = defect per oportunity * 1000000

=0.5349264*1000000
= 5349264

Dpo = total no of defect /total opportunity

= 291/544 = 0.5349264

Sigma level =1.40

14 10/15/2022
 Analyse

1. DCP for Potential Xs

2. Identify Potential Xs
3. DCP for Potential Xs
4. Basic Analysis for Project Y
5. Checking for Impact of ...... on Y
6. Hypothesis Summary
7. MSA results of Impacting Factors

15 10/15/2022
 Identify Potential Xs Analyse

Factors identified through brainstorming

16 10/15/2022
 Basic Analysis of Project Y Analyse
Randomness & Shape Study

Normality Study

Since p -value is less than 0.05, hence the data is not normal.

17 10/15/2022
 Interesting, right?
This is just a sneak preview of the full presentation. We hope you like it!
To see the rest of it, just click here to view it in full on PowerShow.com.
Then, if you’d like, you can also log in to PowerShow.com to download
the entire presentation for free.

18 10/15/2022