LSS Assignment.doc

8/14/2019 LSS Assignment.doc

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Lean Six Sigma (LSS)

2he Pareto Chart a(ove tells us that High *ressure is the highest

contri(utor to the total 'efects%

&e0t the Labelsare not in the ri.ht place%

An' r' are the ,ents

Since this covers 8$9 of the 'efects , 6an ol( shoul' concentrate on these

'efects:

High *ressure

Labels

,ents


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As seen from the information a(ove, since 'ents can (e a safet* ha3ar', the

two main 'efects that 6an ol( shoul' concentrate on shoul' (e High

*ressure in the cans and ,ents% 2he /a(els not in the ri.ht place an' can

(e tacle' as less priorit* 'efect%

Question &

-ap the Greasex production process% tracing !arious processing

stages in!ol!ed Where should Han loo for the root causes

of the can pressure problem" What might be the root causes

of the high pressures in cans"

#ns$er

;n the or.ani3ation lac of


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A(ove is the parameter 'ia.ram showin. various parameters lea'in. to


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.efer belo$ production process/

4ith the .iven information it loos lie followin. two potential reasons for

hi.h pressure

1+ Pressure is .enerate' 'ue to mar(les insertion in to the cancorrect


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Question 0

ased on the data pro!ided ho$ $ell is the process meeting gi!en

can pressure specifications of '2 to 32 *si" What can you say

about pressure !ariation in the can produced by the process"

#ns$er

rom Samples:

Mean thicness of output, 8%?B

Dpper St' /imit 85

Stan'ar' 'eviation of output, ?%1B7

/ower St' /imit 75

+alculations

4e will use E test for Proportion within specifications%

0 F G # 3% H

3 F )0 ! G+"H F )85 - 8%?B+"?%1B7 F $%B1 3 F )0 ! G+"H F )8%?B ! 75+"?%1B7 F

!1%7I 3)$%B1+ F $%7I

3)!1%7I+ F $%$7

2otal area un'er the curve F $%7I - $%$7 F $%BI F BI%9

Process capa(ilit*:

Cp F )DS/ ! /S/+"BH F )85 !75+"BJ?%1B7 F $%?

rom Minita(:

Varia(le & Mean SK Mean St=ev Variance Minimum

4ei.ht 1$$ 8%?B$ $%?17 ?%1B7 17%B 7%$$$

Varia(le Ma0imum Lan.e

4ei.ht I%$$$ $%$$$

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Proportion of cans with wei.hts within 75 to 85 F BI%9

Proportion of cans with wei.hts (e*on' 75 to 85 F $%89

Kstimation of process Mean wei.ht:

4ith I59 C; the limits for mean wei.ht are: 81%?B to 8%77

2hus we can sa* that currentl* the pressure variation is too hi.h (ecause:

1% Process capa(ilit* Cp of $%? is ver* low%

% 4ith current amount of varia(ilit* $%89 parts will (e reecte'%

% 7%19 reections will (e 'ue to overwei.ht cans%

Process mean is towar's the hi.her en' of the ran.e of 75 to 85%

Lefer (elow ta(le in'icatin. stan'ar' 'eviations, P Values, mean num(ers for

all can measurements%

4t clearly sho$s that process mean has been shifted for all cans

*ressure !ariation does not meet Six Sigma le!el

5ariation is due to random noises no special causes% especially since

* !alue is 6772 Stan'ar' 'eviation is also more%

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I


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+an818Mean has (een shifte' an' out of control

+an8&8*rocess shifted% but less !ariation as per mo!ing a!erage

1$


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+an808*rocess shifted $ith huge !ariations

+an898 *rocess shifted $ith huge !ariations

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+an828 *rocess shifted $ith huge !ariations

Question 9

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What should Han do to impro!e the process performance% both in

short term and in long run" :o$ards ambitious goal of producing Six

sigma quality% suppose Han $ould lie to start by meeting the

customer specifications at least ;2< of the time What le!el of

process capability or precision he $ould be needed"

#ns$er

Short :erm -easures

1% 2he* coul' perform a mae"(u* anal*sis to 'etermine if the* shoul' off!loa' the pro'uction to another compan*%

& Con'uct formal e0tensive trainin. of the operator who runs themachine%

0 Accor'in. to the process flow charts, ensure that Manufacturin. an'ualit* (oth are a'herin. to the chec points an' eliminatin. the reect cans

at appropriate sta.es%

9 4or with Maintenance to come up with a Preventive maintenancesche'ule for the ol' )wron.+

2Shift the process to the of the ran.e which is 8$ Psi

=2here is lot of variation with in a can an' across the cans, hence this henee' to control variation (* improvin. processes% 2his variation is ma* (e(ecause of various reasons, some of the reasons in'icate' (elow%

;mprove process for plastic valve assem(l* which is shorin. (urr'urin. assem(l* an' re


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9 2he* can 'o a cost"(enefit anal*sis to see if the* shoul' invest in (ettermachines% 4or with Manufacturin. an' Maintenance to (u* a (ran' new ora secon' han' machine )su(ect to finance availa(ilit*+ which is 'esi.ne'for the @rease0%

2 4or with Nperators an' ualit* Kn.ineers to trac the Process capa(ilit*,

an' Pareto of 'efects to (rin. it un'er control over perio'%

= 2he* coul' start with senior mana.ement to mana.e the compan* (* avisi(le


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Question 2

#lthough the process does not seem to be meeting customer

requirements !ery $ell% does it at least appear to be stable in terms

of

a) 5ariation in cans produced bet$een day>s

b) 5ariation in cans produced $ith in a day"

#ns$er

Lefer (elow ta(le is clearl* (ase' on mean an' stan'ar' 'eviation it is clearthat process has hu.e variations within a 'a* an' across various for 'ifferentcans%

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88?@,88

1B

5aria

$ith

day

5ariation across cans at

different day>s

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