SIPOC diagram

LSSBBManufacturingProject.xlsx

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Welcome

Welcome!
Please read this page (in particular) very carefully.
Instructions
The tabs (bottom of each sheet) in this
document contain all of the deliverables expected of you.
If you need help along the way, look for these special cells that have a red indicator
in the corner. It looks like the "Read me" box to the right:		Read me daniel-munson: Instructor: These cells contain some hints, tips, and self-checks. If you would like to print any of the tips, right click the cell containing the tip and select Edit Comment. Highlight the text, copy and paste in a any text document like WORD for printing.
Simply slide your cursor over the red-cornered cell and you will get more information.
The format for all of the deliverables is the same:
The 'assignment objective' is in black font.
The instructions for that assignment are in green font.
The blue font is the data (where applicable) for completing the assignment.
Software
We are using Excel software for the projects. You may use other software
to complete your projects, but please 'report' your answers in the Excel format
described below.
You may complete your assignments with any version of Excel software.
All assignments can easily be completed with a basic copy of Excel.
There is also an Add-In feature which is available for Excel that can be helpful,
although it is not required. The Add-In feature comes free with each Excel package,
although it may not be currently loaded into your copy.
Following are the simple instructions for loading the Excel Add-ins for both Excel 2003
and Excel 2007 (or later). (Slide your cursor over the red-cornered cells to read)
Excel 2003 or earlier Diane Johnson: Instructor: EXCEL 2003 or earlier Click on the TOOLS tab in the top bar of Excel. If your computer already has the “Data Analysis” option listed, you are ready to go. Your Data Analysis tools have already been added. Under the Data Analysis Function you will find some of the more advanced functions that we will be discussing such as ANOVAs, and t tests. If you do not see Data Analysis listed under the TOOLS tab, I encourage you to go to the Help function in Excel for specific instructions on how to load “the Data Analysis Toolpak” in your version of Excel. Here are the easy standard instructions for Excel 2003 if you need to load the Add-Ins. 1) On the Tools menu, click Add-Ins. 2) In the Add-Ins available box, select the check box next to Analysis Toolpak, and then click OK. 3) When you load the Analysis Toolpak, the DATA ANALYSIS command is automatically added to the TOOLS menu. If your version if slightly different than the above, refer to your HELP function for details on loading Tookpak. See the next spreadsheet at the bottom of this worksheet entitled EXCEL EXAMPLES for an illustration. The Data Analysis function in Excel is NOT required for the completion of this course.	Excel 2007 or later Diane Johnson: Villanova instructor: Excel 2007 or later The Analysis ToolPak is a Microsoft Office Excel add-in program that is available when you install Microsoft Office or Excel. To use it in Excel, however, you need to load it first. 1. Click the Microsoft Office Button , and then click Excel Options. 2. Click Add-Ins, and then in the Manage box, select Excel Add-ins. 3. Click Go. 4. In the Add-Ins available box, select the Analysis ToolPak check box, and then click OK. If you get prompted that the Analysis ToolPak is not currently installed on your computer, click Yes to install it. 5. After you load the Analysis ToolPak, the Data Analysis command is available in the ANALYSIS group on the DATA tab. See the next spreadsheet EXCEL EXAMPLES for an illustration. The Data Analysis function in Excel is NOT required for this course.
Excel Novice - Please read Diane Johnson: Instructor: It is beyond the scope of this Black Belt course to teach students how to perform all of the functions of Excel. The Microsoft web site has excellent FREE tutorials for Excel. https://support.office.com/en-us/article/Excel-training-9bc05390-e94c-46af-a5b3-d7c22f6990bb Or ask a business colleague who is proficient in Excel to show you how to do some of the basic things such as copying, cutting, pasting, copying from sheet to sheet, etc. Please do not expect your Black Belt class instructor to teach you how to use Excel software. That is not the objective of this course. This course will highlight specific Excel commands that are unique to Six Sigma, but it is not the objective of this course to teach basic Excel commands. Please use the suggested resources listed above.
Project Timeline
Remember that the entire project must be
100% correct and complete by no later than midnight EST one week (7 days) BEFORE the last day of class.
THIS MEANS THAT ALL REQUIRED CORRECTIONS MUST HAVE BEEN COMPLETED CORRECTLY - JUST TURNING
IN THE ASSIGNMENT IS NOT SUFFICIENT IF THERE ARE ANY ERRORS ON IT. Most people require 2 - 3 attempts
per assignment to make all necessary corrections - so plan your time accordingly!
Deliverables include:
Project charter (target week 3 or sooner)
SIPOC (week 4 or sooner)
Baseline sigma (week 7 or sooner)
Pareto chart (week 8 or sooner)
Expected Variation (week 9 or sooner)
T Test (week 11 or sooner)
Scatter diagram (week 12 or sooner)
DOE (week 13 or sooner)
Control chart (XmR) ( week 14 or sooner)
Pp Ppk (week 15 or sooner)
How to submit an Assignment
There is a peach colored box for each deliverable.
This designates the assignment to be submitted to your instructor.
Project:	Manufacturing Project
Deliverable:	Improve phase - gen. sol.
Student last name:	Johnson
What is the control chart telling you?
There is a point out of control at subgroup #15. I would try to figure out why that happened. We would also recalculate the control limits because there is evidence the process has changed.
What is the average of subgroup 1?	22
What is the average of subgroup 2?	34
What is the average of subgroup 3?	23
What is the average of subgroup 4?	22
What is the average of subgroup 5?	25
What is the average of subgroup 6?	23
What is the average of subgroup 7?	29
What is the average of subgroup 8?	27
VERY IMPORTANT!! Be sure to submit your assignments for grading as you complete each one and following the schedule for each deliverable - DO NOT WAIT UNTIL THE END OF THE COURSE TO SEND THEM ALL IN. NOTE THAT THE ENTIRE PROJECT MUST BE 100% CORRECT BY ONE WEEK BEFORE THE END OF CLASS OR YOU WILL FAIL THE PROJECT AND THE COURSE. This means that you must submit ALL of your assignments far enough in advance of the project completion deadline to allow time for all necessary corrections to be made. Following the submission schedule is the best way to ensure that you have enough time to finish the project by the completion deadline - failure to meet the submission due dates can result in failing the course. Very few assignments are correct on the first submission and many require multiple rework attempts, so don't procrastinate!

Scatter Diagram 0 0

5 2 6 2 1 4 5 8 2 4 5 2 4 3 2 1

The project

Manufacturing Project
Lovell Levelers, Inc. is a major provider of specialized parts for the automotive industry
LLI's focus is on trucks and RV's along with towing. They also specialize in parts for
tires, wheels and performance handling. LLI’s biggest customer, Specific Motors
was not a delighted customer this month. In fact, last
Monday, the executive vice president of Specific Motors,
Phyllis Kendall, was diverted from a return trip from Singapore
to drop in unexpectedly at the LLI plant. There was nothing
routine about this visit. She made it explicitly clear that
Specific Motors was disappointed with the level of quality relative
to the leveler plates. In particular, she was disappointed with the
current average of rejects at the rate of 1,350 defects per million
opportunities (DPMO) that has created a cost of poor quality of just over $256,000
per quarter for them. She said the industry standard is 50 DPMO and
if we do not get the level of quality to the industry standard within the next
six months, LLI will lose Specific Motors as a customer.
LLI has three main suppliers that they currently use: General Dynamic,
Motonova and Crane Tech
The student will be a Black Belt working for LLI. The specifics about their company:
CEO			Bill Lovell
GM			Mary Nichols
Sponsor			John Hopps
Finance			Cindy Jenkins
Process owner			Leroy Miller
Master BB			Dennis Kens
Manufacturing			Mitch Freese
Design Engineer			Al Nelson
Quality			Debbie Judson
Please 'hand-in' your assignments throughout the course according to the schedule posted. DO NOT SAVE THEM
FOR THE END. The deadline for having all project assignments 100% correct is 7 days prior to the end of the course.

Define (Project Charter)

Objective:
Create a project charter that will motivate management to sponsor the project.
Your project charter should also define the boundaries of the project, and what the expected end result.
If the boundaries are too wide, the project may fail because you're trying to do too much.
If the project boundaries are too narrow the project may not achieve the desired results.
Your project charter should also excite people to become members of your team.
Instructions for you:
Create a project charter	"Create a charter?" daniel-munson: Instructor: Information about project charters can be found in recorded lectures in week 3, in your online textbook and study guides, and in the week 2 virtual class.
Create a project charter based on the information on "The Project" tab.
The six blocker template taught in this course includes a project schedule and a list of stakeholders.
We are not interested in those details for this simulation, but we do want to see what you
come up with for the other four (4) items: Problem statement, business case, goal and project scope.
TARGET ASSIGNMENT DATE - Submit in Week 3 or earlier
Project:	Manufacturing
Deliverable:	Project charter
Student last name:
What is the business case? (Use no more than two sentences.)
Specifc Motors, our largest and most important customer is dissatisfied and stated they will discontinue business with us next year. They are not happy with our high rate of rejections of 1,350 DPMO at a COPQ of over $256,000.		"Business Case?" daniel-munson: Instructor: I am your sponsor for this project. If I was your actual sponsor, I would be very busy and would need to make decisions quickly. I would need to know what this project is all about and how it impacts the strategic objectives of the organization. Please limit this to a sentence or two. MAKE IT CLEAR AND CONCISE!
What is the problem statement? (Use no more than two sentences.)
Each quarter, we have produced an average of 1,350 DPMO of rejected leveler plates, which exceeds the industry standard of <50. Last quarterly reports displayed a COPQ of just over $256,000.		"Problem Statement" daniel-munson: Instructor: Acting as your real-world sponsor, I would need to be sold on why we need to do this project. I wouldn't have time to read long explanations. I would need a short, to-the-point compelling reason why we need to do this. In the problem statement, we 'sell' the need for the project with specific and measureable data. MAKE IT CLEAR AND CONCISE!
What is your goal statement? (Use one sentence.)
By March 20, 2021, we will create a process that will ultimately reduce the defects of the leveler plates to less than the industry standard of 50 DPMO.		"Goal Statement" daniel-munson: Instructor: What is your target improvement for this project, including a target date? Remember to link your goal to the problem statement and to keep your goal statement "SMART"!
What is the project scope? (This is not your goal statement! Use one sentence.)
Immediately identify the root causes of the defects, and communicate with our suppliers to ensure we are receiving quality materials and ensure this project is completed within six months.		"The project scope?" daniel-munson: Instructor: This needs a lot of thought. As your sponsor, I do not want to see 'scope creep.' "What's scope creep?"…please read on... What the scope is not: -It is not merely a timeline (i.e., when the Six Sigma project is to begin and when it is expected to end.) -It is not restating the problem being attacked. The scope defines the boundaries of the project--usually some beginning point and ending point. For example, if I were leading a project to improve the delivery of course materials to students, I would have the following boundaries: The process (IN THIS PROJECT) starts: When the customers says, "Yes, I am interested in enrolling." The process (IN THIS PROJECT) ends: When the customer receives the box from UPS that contains their handbook and CD's. The project stays within that confinement. Included might be: Enrollment process, warehousing process, accounting process, and UPS delivery process. What would NOT be included: -Errors in the handbooks or CDs. -User friendliness of the materials. Any of these items would be fine for some OTHER PROJECT. “Scope creep” is a common phenomenon with teams, but should be avoided. If the scope was predetermined to be as stated above, the team should stick to the confines of that scope. If they do not stick to it, eventually the team might begin to work on “login times.” Then, they might add to that the time it takes the enrollment rep to “close the sale.” Then, they might add to that making sure all materials are delivered error free. ...and on and on it goes. Thee scope creeps on and on. The team soon becomes frustrated and the probably of failure increases. It is best to establish the scope--then, the team needs to stick to it. You may also include important constraints/assumptions including the staffing allocation (team composition) as well as the budget constraints in a scope statement.
	daniel-munson: Instructor: Information about project charters can be found in recorded lectures in week 3, in your online textbook and study guides, and in the week 2 virtual class.	daniel-munson: Instructor: I am your sponsor for this project. If I was your actual sponsor, I would be very busy and would need to make decisions quickly. I would need to know what this project is all about and how it impacts the strategic objectives of the organization. Please limit this to a sentence or two. MAKE IT CLEAR AND CONCISE!	DO NOT SEND ANY EXTRA ATTACHMENTS UNLESS YOUR INSTRUCTOR SPECIFICALLY ASKS YOU TO!!
Please 'hand-in' your assignments throughout the course.
DO NOT SAVE THEM FOR THE END.
Procrastinators: The deadline for having all project deliverables 100% correct
is 7 days prior to the end of the course.

Define (SIPOC)

Objective:
We want to view the process from a high level in order to see the major process elements.
SIPOC - Suppliers, Inputs, Process, Outputs, Customers
Instructions for you:
Create a SIPOC map of the process based upon the manufacturing case study write-up (found at
"The project" tab). Feel free to use your imagination in doing this piece of the project.
Draw upon your own experience from being in a manufacturing facility
the 'suppliers', 'inputs', 'process', 'outputs', and 'customers.' Note: Normally the
SIPOC map is constructed horizontally. When mailing this deliverable to your instructor,
it formats better vertically.
TARGET ASSIGNMENT DATE - Submit in Week 4 or earlier
Project:	Manufacturing
Deliverable:	SIPOC
Student last name:
Suppliers:		HINT! Lois Jordan: Suppliers provide things that are used during the process you outlined below.
(At least 3)
Inputs:		HINT! Lois Jordan: Inputs are used during the process you outlined below.
(At least 3)
Process Step 1:
Process Step 2:
Process Step 3:
Process Step 4:
Process Step 5:
Process Step 6:
Process Step 7:
Process Step 8:
Outputs:		HINT! Lois Jordan: Outputs are created by the process you outlined above.
(At least 3)
Customers:		HINT! Lois Jordan: Customers receive the outputs created by the process you outlined above.
		Lois Jordan: Suppliers provide things that are used during the process you outlined below.	Lois Jordan: Outputs are created by the process you outlined above.	Lois Jordan: Inputs are used during the process you outlined below.	(At least 3)
DO NOT SEND ANY EXTRA ATTACHMENTS UNLESS YOUR INSTRUCTOR SPECIFICALLY ASKS YOU TO!!
Please 'hand-in' your assignments throughout the course.
DO NOT SAVE THEM FOR THE END.
The deadline for having all project deliverables 100% correct
is 7 days prior to the end of the course.

Example of

a deliverable