Professional Documents
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Process Owner: AK
Green Belt: DS
Sigma Trac ID # : 200601193715
Project Schedule
Plan
Completion
Definition:
Measure:
Analyze:
Improve:
Control:
Validation:
1
Date
Actual
Completion Date
16/02/06
16/02/06
08/04/06
08/03/06
31/05/06
23/05/06
23/06/06
05/07/06
28/07/06
29/09/06
CI Statement of Work
Date printed:
Project Charter/Statement of
Work
5/15/06
Project Title:
Location:
Malaysia - KL
Phase
Analyze
Project #
200601193715
Type:
Black Belt
Originator:
Customer Quality Focus:
Create Date:
J amilah Haron
No
2/2/06
Rollout Type:
Standard
#N/A
#N/A
2.00601E+11
Customer Y (s):
Quality
Business Y (s):
Quality
Problem Statement: 90 pieces of door panels are returned to J CAI due to torn caused by hitting
delivery rack
Project Objective /
Suspected Root
Cause:
Primary BBP metric 4 - Scrap and I nv Loss Per EQU
impacted:
BBP Product Line:
I nteriors: Door Panels
23
TEAM
Process Owner:
Azhari Kayoon
Black Belt:
CI Manager:
Green Belt:
2 (b)
Assessment Agreement
Within Appraisers
95.0% CI
Percent
95
95
90
90
85
80
75
75
2
Appraiser
Measure
85
80
95.0% CI
Percent
100
Percent
Percent
100
Appraiser vs Standard
2
Appraiser
Defne
Proportion
0.030
0.025
UCL=0.02574
0.020
_
P=0.01921
0.015
LCL=0.01267
0.010
0.005
1
0.000
1
Sample
Tests performed with unequal sample sizes
Measure
Target
Process Flow
PP sheeting
Measure
Analyze
Causes
Analyze
Null
Hypothesis
Alternative
Hypothesis
Data to
verify
Data
Type
Verifcation
Verification
Method
Results /
Conclusion
Cause
N
o
Potential
Cause
1.
Defect ratio no
change
Defect ratio
lower
Reject
data
Attribute
1-proportion
P-value = 0.00
Yes
2.
Defect ratio no
change
Defect ratio
lower
Reject
data
Attribute
1-proportion
P-value = 0.00
Yes
3.
Rough surface
(after trimming)
Defect ratio no
change
Defect ratio
lower
Reject
data
Attribute
1-proportion
P-value = 0.00
Yes
Verifed action
( = 0.05)
Improve
Improvement is
statistically significant
Verifed action
( = 0.05)
Improve
10
Improvement is
statistically significant
Verifed action
Improve
11
Improvement is
statistically significant
Potential Actions
Y= Torn defect at 1J product (CPPM)
Y
Improve
Torn defect
12
Cause
Potential Action
Effective
-ness
(High/Med/
Low)
Ease to
Implemen
t (High/Med/
Cost to
Implemen
t (High/Med/
Low)
Low)
Safety
Impact
(High/Med
/Low)
High
Med
Low
Med
High
Med
Med
Low
High
High
Med
Low
Improve
13
Before
Completed Action
After
Wrapped rack pillars
Completed Action
Improve
Use conventional
knife
14
Before
After
Trimming Jig
Monitoring Process Y
Y = Torn Defect (CPPM) 1J
P Chart of Return reject (torn)
Oct
0.030
Apr
1
0.025
Proportion
0.020
0.015
77% reduction
0.010
Control
0.005
15
UCL=0.00444
_
P=0.00132
LCL=0
1
1
0.000
1
5
6
Sample
10
16
Who
Due date
1.
Azhari
End of Aug 06
2.
Dewa
End of Aug 06
Results Summary
Sigma Level (ST)
Before
2.07
After
3.10
PPM (LT)
284,339
65,522
Before
Cost of Poor Quality
(Cost Reduction)
Y1
17
RM 44,197
284,339ppm (LT)
After
% change
RM 0
65,522ppm(LT)
100%
77%
Next
Steps
Issue List
Issue / Request
1
18
Suggested Action
Owner
AK
On going
Countermeasure is implemented
continuously.
DS
(CI)
3rd wk of Aug 06
WF
ME
3rd wk of Aug 06