six sigma
Malansari23
question_1_step_3-.pptxSix Sigma: Case Study #1
Professor: Dr. Govind Bharwani
Due: 9-22-16
By: Darin Schwieterman
Presentation Code: dccs1092216
http://rube.asq.org/2011/09/design-of-experiments/ford-team-project-builds-relationships.pdf
Company Profile
Company name: Ford
Founder: Henry Ford in 1903
Location: United States
Six Sigma: Started in the 1999
Formally Launched Six Sigma in January of 2000
HP Pelzer automotive systems
Supplier of automotive interior trim
Drivers for change
Ford Fiesta
pre-launch reviews pinpointed a concern
the vehicle’s carpet contained visible brush marks
Six Sigma Project
DMAIC is one of the six sigma improvement process
Defining the Stakeholders
Internal stakeholders
Fiesta program team
the Fiesta assembly plant
Body Six Sigma team
External stakeholders
HP Pelzer
End customer
Measuring Critical-to-Quality Factors
Focused on the automotive carpet manufacturing process
The team developed a fishbone diagram and an f(x) cascade chart
Engineering-based flowchart
Used why and how to identify root causes
Flow Diagram
Analyzing for Root Cause
First four runs took three hours to finish
analysis for softness/plushness was less complex with only two significant effects
Improving Carpet Quality
Two new optimized factor settings for the needler.
deliver significantly higher levels of quality for both brush marks and plushness/softness
Controls to Sustain Improvements
Communicating the new process to HP Pelzer employees
Programming the needler with the new settings
Monitoring the quality of the carpets produced
Monitoring the condition of the needler
Six Sigma Tools
Fishbone diagram
Cause and Effect
Control chart (SPC)
Pareto chart
Design of Experiments
KPIV and KPOV
KPIV
Variation in
brush marking rating
Softness rating
KPOV
Improve brush markings
Results achieved
protecting customer satisfaction
avoiding warranty claims
eliminating scrap materials
A stronger relationship with the supplier
Increased technical knowledge
The creation of a new optimization process for the supplier
A great product for customers
The creation of a Six Sigma program by HP Pelzer to increase efficiency and improve quality
Lessons Learned
Team used quality tools to reduce the defect rate to zero
Six sigma tools can be used to identify and track problems in company's
Questions?
