Leadership development 2500words

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00_LSS_Group_Assignement.pdf

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6σ

Yin YangLean Six g Sigma

LEAN

Group Projectp j

LIM CHIN GUAN 1

Lean Six Sigma Overview

TOPIC 8 (A) Oral Presentation On Case Study (B) Review The Module

Group Project Brief One of the paper helicopter design by Helihex received customer complaints that it is not able to stay aloft in the air for long. The customers complained that the paper helicopter descends too fast when drop from a height of 2m above ground At the same time thedescends too fast when drop from a height of 2m above ground. At the same time, the paper helicopter sales starts to decline due to customer returns and switching to buy from the competitors.

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Lean Six Sigma Overview

TOPIC 8 (A) Oral Presentation On Case Study (B) Review The Module

Group Project Brief Current design of paper helicopter. Materials : 80g Paper, Ruler, Paper Clips, Scissors .

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Lean Six Sigma Overview

TOPIC 8 (A) Oral Presentation On Case Study (B) Review The Module

Group Project Brief You group has been tasked by the management to lead a cross functional continuous improvement team to review this customer complaints and improve the paper helicopter aloft time The current helicopter aloft time is 3 0 sec +/ 0 5 secaloft time. The current helicopter aloft time is 3.0 sec +/‐ 0.5 sec.

As a Lean Six Sigma Yellow Belt, you are required to utilize the following DMAIC methodology to resolve this customer complaints. 1. Define – Project charter 2. Measure – Process map and C&E diagram to determine the critical factors 3. Measure – Initial Capability / Performance 4 Analysis – Data Analysis of Potential Root‐causes4. Analysis Data Analysis of Potential Root causes 5. Improve – Proposed Solutions / Design 6. Control – Control plan & Final Capability / Performance

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Lean Six Sigma Overview

TOPIC 8 (A) Oral Presentation On Case Study (B) Review The Module

Group Project Brief CURRENT HELICOPTER DESIGN Dimension Value (mm) R1 45R1 45 R2 90 H1 60 H2 90 H3 185 T1 30 T2 30 T3 30T3 30

Paper : 80g White Paper Paper Clip : 1 Paper Clip

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The lecturer will advise the new aloft time as the project goal based on a new set of dimensions for this assignment.

Lean Six Sigma Overview

TOPIC 8 (A) Oral Presentation On Case Study (B) Review The Module

Class Assignment • Students are required to form groups of 3 to 4 members for the group project. • The group size will be determined by the lecturer depending on the class size and at

his/her discretionhis/her discretion. • Each group is to submit the group member’s name to the lecturer on Session 2. • All members are to remain in the same group and any swap of group members must be

done with the consent of the lecturer. • Students are expected to manage their group members throughout the project in terms

of contribution. The class assignment shall be submitted on Session 7/8. • Late submission is considered null and void.

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Lean Six Sigma Overview

TOPIC 8 (A) Oral Presentation On Case Study (B) Review The Module

Guidelines for Group Project 1. Each group shall deliver a presentation on how the team utilize DMAIC methodology to

improve the helicopter aloft time. 2 The target audience for the presentation shall be the company’s management team2. The target audience for the presentation shall be the company s management team.

The students could assume the role as Lean Six Sigma Yellow Belts assigned by the company in studying the situation and develop proposed solution. The presentation should demonstrate how the team utilize the DMAIC methodology to systematically resolve the issue. The students as a group need to clearly communicate to convince the management team to adopt what they are attempting to achieve with their recommendation in their presentation.

3 The presentation should also have a good balance of pertinent diagrams charts and3. The presentation should also have a good balance of pertinent diagrams, charts and tables to make it looks professional and reading interesting. The presentation should be less than 20 slides excluding appendices. The presentation pack shall be submitted on Session 7/8. Late submission is considered null and void.

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4. Each group is to make a class presentation on Session 8 for others to benefit as well as for clarifications on their report by the lecturer.

Lean Six Sigma Overview

TOPIC 8 (A) Oral Presentation On Case Study (B) Review The Module

Six Sigma Methodology • Define

We start by identifying the customer and their requirements. We define the project including the problem the goal and the scopeincluding the problem, the goal, and the scope.

• Measure We determine what / how we will measure and verify that our measurement system is good so that the data can be trusted.

• Analyze Determine how well the current process is doing (the sigma). Identify root causes for defects.

• ImproveImprove Develop the process by eliminating the root causes that are driving defects.

• Control Put controls in place to make sure change lasts and the problem doesn’t come back.

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Lean Six Sigma Overview

TOPIC 8 (A) Oral Presentation On Case Study (B) Review The Module

Key Players • Sponsors:

executive leaders to commit to Six Sigma and to promote it throughout the organization • Champions:• Champions:

responsible for Six Sigma strategy, deployment, and vision and removing barriers • Master Black Belt:

to serve as trainer, mentor, and guide • Black Belts:

to work full‐time on projects • Green Belts:

to work with black belts on projects part‐timeto work with black belts on projects part time • Process Owner:

owner of the process, product, or service being improved – to sustain long‐term gains from projects.

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• Yellow Belts: as a core team member or subject matter expert on a project or projects

Lean Six Sigma Overview

TOPIC 8 (A) Oral Presentation On Case Study (B) Review The Module

Project Format • Define – Project charter • Measure – Process map and C&E diagram to determine the critical factors

Initial Capability / Performance– Initial Capability / Performance • Analysis – Data Analysis of Potential Root‐causes • Improve – Proposed Solutions / Design • Control – Control plan & Final Capability / Performance

Dump Manager Always Ignore Customer Define‐Measure‐Analysis‐Improve‐Control

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Lean Six Sigma Overview

TOPIC 8 (A) Oral Presentation On Case Study (B) Review The Module

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Lean Six Sigma Project Charter Title: Reduce Scrapped Cookies in NW Region BB/GB: B. Thornton

Business Gap

Milestones/Timeline: Scheduled Actual

Our bakeries scrap approximately 25% of all cookies baked. Scrapped cookies limit our ability to remain profitable while we are being pressured to reduce prices by our competitors. S

Financial Impact $204,400 in direct savings based on current production rates

Milestones/Timeline: Scheduled Actual Define Tollgate Review: June 4, 2007 6-4-07 Measure Tollgate Review: July 9, 2007 Analyze Tollgate Review: August 13, 2007 Improve Tollgate Review: September 10, 2007 Control Tollgate Review: September 24, 2007

Customer

Scrapped cookies have always been an issue and it has become worse since new ovens were installed. Based on a Pareto Analysis we will focus initially on the NW Region.

Defects & Metrics

Project Scope/Boundaries:

Process Start: Mix Ingredients Process Stop: Bake Cookies In Scope: Chocolate Chip Cookies in all NW Bakeries Out of Scope: Packaging

External: Grocery Stores, Consumer

Internal: Regional General Manager

Defects: Scrapped Cookies

Problem Statement

Team: B. Thornton (BB), A Yamoto (Process Owner), W. Houston (SME), P. Smith (SME), G. Hines (SME), L. David (SME)

Champion: T Wong

p g gDefects: Scrapped Cookies Primary: Scrap Rate for Cracked Chocolate Chip Cookies (CCCC) Secondary: Returns dues to CCCC’s Consequential: Taste, Chewiness

Champion: T. Wong

Objective Statement

The scrap rate due to cracked chocolate chip cookies in the NW bakeries was 15% for the past 12 months based on daily scrap reports.

Reduce the scrap rate due to cracks from 15% to 8% byReduce the scrap rate due to cracks from 15% to 8% by 11/12/07 as measured by the daily scrap report

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Lean Six Sigma Overview

TOPIC 8 (A) Oral Presentation On Case Study (B) Review The Module

Your action: • Look for your project partner (5 maximum) • Download the project charter template from websiteDownload the project charter template from website • Fill the project charter template • Email to Lim Chin Guan, [email protected]

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