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six20sigma20cs120jbcs1092216.pptxSix Sigma and Ford Motor Company Wasted Paint during Manufacturing
Jacob Niekamp
September 21, 2016
JBcs1092216
Founded in Dearborn, Michigan on June 16, 1903
# 8 on the Fortune 500
Vehicles, Engines, Replacement Parts, Distribution
Started Six Sigma in 1999
Ford Motor Company, inc.
Drivers for change
Phong Vu (Director of quality for trucks) was looking for new ways to improve quality
Saw the success in other large companies
10,000 employees trained with a $6 million license purchased
Six sigma project
Reduction of painting cost (Paint consumption)
Savings of $1.5 million a year
Better met customer needs
Reduction of defective parts
Healthier for the environment (VOCs)
Savings of 50 Kg a year
| Team | Function | Team Role | Task and Involement |
| M. Fischer | Engineer | Black Belt | Lead the project Data plan Tools and methods |
| Eisele | Master Black Belt | Master Black Belt | Input of experience Coaching by tools and methods |
| R. Höfner | Area Manager | Project Champion | Provide resources for project |
| R. Schmitt | Maintenance | Process Owner | Provide resources for project |
| H. Nagel | Engineer | Production, Subject-matter Expert | Test trials from production side |
| W. Kretschmer | Engineer | Engineering, Subject-matter Expert | Consumption recording Research for automatic equipment |
| S. Schmitt | Foreman | Maintenance, Subject-matter Expert | Test trials and research |
| J. Buchholz | Foreman | Maintenance, Subject-matter Expert | Test trials and research |
| F. Scholtes | Foreman | Maintenance, Subject-matter Expert | Test trials and research |
| U. Michelbach | Foreman | Maintenance, Subject-matter Expert | Test trials and research |
| S. Bronder | Financial Analyst | Financial Analyst | Cost-benefit analysis |
| J. Pink | Superintendent Supplier | Product expert | Test trials Material properties |
DMAIC Testing
Define – 3.74 kg/unit to 4.18 kg/unit increase / formed a team
Measure – Compiled statistical data and defined possible waste areas
Analyze – Identify sources of wasted paint
Improve – Upgraded valves and improved electrostatic process
Control – Monitoring system on the entire paint process
Six sigma tools used
Cause-and-effect Diagrams
Identifying the root causes of consumption and performance issues
Process Map and Flowchart
Visually able to see the paint movement through the process
Hypothesis Testing
Tested six possible wastes in paint
Kpiv and kpov
KPIV
1. Daily basecoat consumption.
2. Paint film thickness check.
3. Consumption per robot.
4. Consumption per manual painter.
5. First-time through rate versus consumption.
6. Application equipment.
KPOV
1. Reduction in paint consumption
Results achieved
Reduction of $2 million annually
Customer satisfaction 129.000 ppm reduction
VOCs reduced 70.000 kg annually
Passed all set goals
Lessons learned
Diversity within a Six Sigma team is vital for the success with the project
Greater diversity within the team allows a variety of skills and experience to be used to complete the project.
A balanced team is one of the best assets for the completion of a Six Sigma project
Questions?
