【正文】 1 S ix S ig m a P r o g r a m m eG r e e n B e l t P r o je c tF i na l R e p o r tS t e p h e n D a l eT r a in i n g w a v e s t a r t d a t e 1 5th F e b r u a r y 2 0 0 0S C R A P R E D U C T I O NE L E C T R I C A L D E S I G N F A U L T SS S D B P R O J E C T R E F : 2 6 1 0P r o je c t R e f : G B 0 0 1 / 0 0S t a r t D a t e : 1 5 . 0 2 . 0 0P l a n n e d C o m p l e t io n D a t e : 3 1 . 0 5 . 0 0C u r r e n t D a t e : 1 . 0 6 . 0 0G r o u p : I n v e n s y sD iv is io n : In d u s t r i a l D r iv e sB u s in e s s U n it : B r o o k C r o m p t o nC o m p a n y : B r o o k C r o m p t o n ( G u is e l e y )S u b m it t e d b y : S t e p h e n D a l e D a t e : 1 . 0 6 . 0 0G r e e n B e l t 2 1. PROJECT DEFINITION......................................................................... 4 ........................................................................... Problem Statement 4 ............................................................................. Problem Objective 4 ...............................................Project selection and Pareto Analysis 4 2. CONTROL MEASURES AND SECONDARY BENEFITS ......................... 8 .......................................................................... Defining the metrics 8 ................................................................................... Primary Metric 8 ............................................................................... Secondary Metric 9 ............................................................................. Process Capability 10 .....................................................................Other business benefits 10 3. TEAM DEFINITION AND SELECTION ................................................. 11 ........................................................................................... Definition 11 ............................................................................................ Selection 11 4. PROCESS MAPPING AND CAUSE amp。 EFFECT ANALYSIS .................. 12 ............................................................................... Process Mapping 12 .................................................................... Cause amp。 Effect Analysis 16 5. CSM amp。 FMEA ANALYSIS .................................................................. 18 ......................................................... Characteristic Selection Matrix 18 .................................................. Failure Modes and Effects Analysis 20 6. CONTROL PHASE ............................................................................. 25 .............................................................................. FMEA Action Plan 25 3 ........................................................................ Details of action plan 26 ......................................................Savings plan and savings to date 28 4 1. PROJECT DEFINITION . Problem Statement During the period Jan – Dec 1999, $29,407 Scrap/Rework costs were incurred as a result of Office related problems. Of this $20,799 were caused by Electrical Design faults, of which fault code 61E (Quality Improvement Notes – Connection Error) accounted for $9,973. This is % of all ELD faults and % of all Office related errors. . Problem Objective Reduce Scrap/Rework costs attributed to fault code 61E by 50% by 31st May 20xx yielding direct savings of $5,000 . . Project selection and Pareto Analysis This project was selected because there was perceived to be an increasing amount of time spent on rework by the Winding Department due to incorrect connections being specified on orders. Historical data was collected over a period from January 1999 to December 1999 in the form of Quality Improvement Notes. Analysis of the data was done using Pareto Charts in order to determine the main aspects of the problem that impact most on the business in relation to scrap and rework. 5 . First Level Pareto Analysis The first level Pareto Chart above shows that Electrical Design was the source of approximately two thirds of all Main Office related errors, and the second level Pareto Chart below shows that fault code 61E was the largest single error of all Main Office errors. Both of these Pareto Charts are shown by the value of scrap and rework. Fault code 61E relates to incorrect connection errors on the Quality Improvement Notes. ELDTSGCMLDEVOt her s2 0 7 9 9 . 1 4 3 1 7 . 9 2 2 0 6 . 4 1 4 1 7 . 3 6 6 6 . 17 0 . 7 1 4 . 7 7 . 5 4 . 8 2 . 3 7 0 . 7 8 5 . 4 9 2 . 9 9 7 . 7 1 0 0 . 001 0 0 0 02 0 0 0 03 0 0 0 002 04 06 08 01 0 0R e j / R e wV a l u eP e r c e n tC u m %Percent$ ValueO f f i c e r e l a t e d R e j e c t / R e w o r k 1 9 9 9 ( V a l u e ) 6 . Second Level Pareto Analysis 61E61M6063Ot her s9 9 7 3 . 3 1 5 3 5 9 . 7 1 3 9 9 9 . 9 4 1 3 3 7 . 1 2 8 7 3 6 . 7 33 3 . 9 1 8 . 2 1 3 . 6 4 . 5 2 9 . 7 3 3 . 9 5 2 . 1 6 5 . 7 7 0 . 3 1 0 0 . 001 0 0 0 02 0 0 0 03 0 0 0 002 04 06 08 01 0 0F a u l tC o u n tP e r c e n tC u m %Percent$ ValueO f f i c e r e l a t e d R e j e c t / R e w o r k b y f a u l t c o d e 1 9 9 9 ( V a l u e )Machi neVeserHand2 2 65 5 2 75 8 1 6 2 . 04 7 . 85 0 . 31 0 0 . 0 9 8 . 0 5 0 . 37 0 0 06 0 0 05 0 0 04 0 0 03 0 0 02 0 0 01 0 0 001 0 08 06 04 02 00D e f e c tC o u n tP e r c e n tC u m %Percent$ Value6 1 E F a u l t s b y W i n d i n g T y p e ( J a n 1