critique a six sigma study
rana900
six_sigma_dmaic_project_-_copy.pptxFoods Case Study
What to cover
Executive summary
Define Phase
Measure Phase
Analyze phase
Improve phase
Control Phase
Conclusion
1. Executive Summary
In December 2008, the company began to receive heavy surcharge from local authorities because of their poor water quality, mainly due to an excess of biological waste entering the sewer system.
Biological Oxygen Demand (BOD) The amount of oxygen needed by bacteria to decompose all the solid wastes in wastewater. Accounted for 74% of the resulting fees. The total bill for poor water quality reached $204,000 in 2009.
A six-sigma team was tasked to extremely reduce the BOD, after 6 months they reached 70% with a goal of 95%.
2. Define Phase Project Charter
| Project Name | BOD Reduction at Kahiki Foods | Commencement Date | Sep, 2009 |
| Project Sponsor | Kahiki Foods | Completion Date | Dec, 2010 |
| Expected Hard Cost Reduction | $195,000 | Expected % Reduction | 95% |
Project Mission
The main objectives are:
Intense reduction in solid waste entering floor drains.
Increase output at different plant processes.
Green initiative for the organization.
$195,000 hard cost reduction.
Problem Statement
Per local authorities BOD levels shouldn’t exceed 250mg/L
Kahiki had BOD waste levels of 3864mg/L, 1546% higher than upper spec limit
The source of the waste was obviously originating from inefficient floor drain management
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Goal Statement
At least a 50% BOD reduction in 6 months and establishing a sustainable system able of reaching the goal of 95% reduction.
Process map
SIPOC map
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3. Measure Phase
The waste removal system doesn't meet the spec.
Process Capability Charts
Measurement Plan
Demand Analysis
Metrics Used To Determine Water Quality
Biological Oxygen Demand (BOD)
Total Suspended Solids (TSS)
Total Kjeldahl Nitrogen (TKN)
BOD Process Capability Charts
TSS Process Capability Charts
Measurement Plan
N/B In any area of concern, should there be a negative response on any unit, the unit is rendered incomplete and therefore a defect.
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Data Collection Challenges
System changed in 2007.
Standard sampling schedule 3 site visits/year moved to monthly.
Data collection visibility most critical points came from cleanup shift.
The above assessment was done by five individuals who were, one hired external expert, two quality assurance officers at the state government, while two are community professionals. MSA is an experimental process and require more views from different quotas of different levels of understanding to make independent judgments on quality (McCarty, 2005).
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4. Analyze Phase
5 Why Analysis.
FMEA.
Gap analysis.
Fishbone diagram.
Hotspot heat map.
Regression Analysis.
Benchmarking.
5 Why Analysis
Plant Floor Drain Hotspot Heat Map
5. Improve phase
Improved Solid/Liquid Separation.
Reducing Waste Creation.
Employee Training.
Best Practice Identification.
WAP Committee: A "Waste Awareness Program“.
Error Proofing: Adding visual SOP's, closing off drains and posting metrics.
5. Improve phase
6. Control Phase
Post Improvement Results:
BOD(3/15/10): 1375 mg/L=70% Reduction, actually it’s = 64.41%
TSS(3/15/10): 790 mg/L= 61% Reduction
Expected Hard Cost Reduction 2010 = $178,365
Control Plan Element 1: Continued employee training
Control Plan Element 2: Sustainability hinges on employees active in the solution process.
Control Plan Element 3: Error proofing
Control Plan Element 4: Accountability is paramount
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7. Conclusion
The case yield good results and reached its goal of 50% reduction in BOD waste level after 6 months, but the diagrams and various analysis methods mentioned throughout the study are not presented which can be misleading.
The study is much simpler to execute than presented to be.
Thank you
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