six sigma
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question_1_step_3.pptxCASE STUDY 1 Six Sigma at Tenneco Alex Kinnaird Samuel Salchak
AJSDCS1091916
Company Profile
Global provider of Exhaust and suspension systems
93 facilities
15 engineering centers
6 continents
Annual revenues of over 8.4 billion USD
2
Drivers For Change
Reduce Scrap, Rework, and Costs
Various sizes of exhaust tubing produced high levels of scrap
2.5-inch tubing saw highest levels out of all sizes
Six Sigma Project
Reduce Scrap on the 2.5 inch exhaust system by 50%
Common cause of scrap is split tubing during manufacture
Team led by Tenneco MBB
Black Belts
Process owners
Engineers
External Experts
Used Minitab Statistical Software
DMAIC
Define
Process map to outline manufacturing steps
Outside consult used for technical aspects
Measure
Gather data during production, especially on defect parts
Analyze
Using Minitab software identify areas causing defects
Improve
Short run production with more advanced R&R
Control
Maintain optimized results over time
Tools Used
Control Charts
Scatter Diagram
Histograms
Hypothesis Testing
Gage R&R
6
Input/Output
KPIV – Common Cause Variation
Variation in tool setup and procedures
Ex. Pipe insertion depth and tool stick-out length data gathered before procedure
Variation in weld zone temperatures
Constant temperature data gathering during procedure
Variation in tooling curvature
Ex. Diameter and wall thickness of pipe data gathered after procedure
KPOV
Reduce 2.5 inch steel tubing scrap by 50%
Results Achieved
Team achieved goal of reducing scrap by 50%
P Chart used to verify results
Customer departments were more efficient
Process implemented into sister facilities
Lessons Learned
Make a team from all levels for analysis
Document solutions to improve results on other project lines and production locations
Computer software programs are powerful analysis tools
Questions?
