Lean Six Sigma

Cricket Ball Manufacturing

Part 1 – Cause and Effect Matrix

Research the process for manufacturing cricket balls (either Kookaburra or Dukes – you choose). YouTube has several videos on the topic.

Based on your research:

Create a simple flow chart of the process

Create a list of the Key Output Variables and estimate the customer priority for each output. (NOTE: You do not have to justify the estimated value.  It is expected that there are at least 4 Key Outputs)

Based on the process list the Key Input Variables by process step

Create a Cause and Effect Matrix using the information that you gathered in your research of the process (NOTE: It is not important that you research the strength of the relationships in depth, it is more important that you perform all of the calculations within the matrix. So “guessing” the strength of the relationships is acceptable)

Based on the work that you have done clearly identify what the next steps should be if the desire is to improve the process to better satisfy customers’ needs.

Part 2 – LSS Metrics

A cricket ball manufacturing company has decided to diversify its operations and use its knowledge to manufacture softballs for the North American market. They have launched the product but are concerned that the cost of poor quality is prohibitive, and they wish to reduce scrap and defect rates.

A simplified view of the process is shown:

The following table contains some of the process information. 

Step Units Defects Opps/Unit In Process Yield dpu RTY

Wind Cores 1100 91 4

Prepare Leather 1350 80 7

Print Logo 1600 256 14

Affix Cover 1400 51 4

Fill in the blanks in the table

If 50 defectives are found out of 1000 units inspected at Final Inspection

What is the overall dpu?

What is the RTY of the process?

What is the DPMO of the process?

Where in the process should the improvement efforts be focused? Justify your answer.