MEASURE STAGE

MEASURE STAGE

The goal of the Measure phase of a Six Sigma DMAIC project is to get as much information as possible on the current process so as to fully understand both how it works and how well it works. This entails three key tasks: creating a detailed process map, gathering baseline data and summarizing and analyzing the data.

 The Measure Stage date have been gathered over the last three months and represents number of Total Measurements and Total Re-measurements. Since the problem have been highlighted we can observed major difference between the beginning of the project and now. The number of re-measurements is declining, as project is still in progress.

                                                                                                   CTQs

 During the Define Stage, the project team established CTQs representing the customer expectation for quality. The CTQ measures and specifications will be used to calculate a process sigma score for the baseline process, so gathering data on those specific measures is a primary focus at this point in the DMAIC project.

We have calculated Total Labour Cost for Total Measurements, Re-measurements and for Good Measurements to see what how much money the company XYZ is wasting on measurements errors.

DPMO

 At this stage, the collected data is evaluated and sigma is calculated. It gives an approximate number of defects. There are 20 opportunities for a measurement error during the MicroVu process. (More details in the Interim Report).

FY Final Yield   

Final Yield and other yield metrics served as baseline scores Measure Phase. we have calculated Yield for further analyzes of the process progression.

Yield Process

Define Stage

Background:

The company XYZ has a focus on cost, improving efficiency, reducing waste (re-measures – waste of time and waste of labour) and implementation of Six Sigma elements.

Project identified a significant opportunity in reducing re-measures and increasing MicroVu availability.

Manufacturing and Quality Assurance raised a problem that a large number of re-measurements are occurring at the MicroVu.

Problem statement:

The existing manufacturing MicroVu is not optimized in terms of correct measurement for range of units being measured, which is contributing to significant labour wastage and equipment availability seen in the department. The problem has been observed over the three months on three shifts (Days, Evenings and Nights).

In XYZ company, there are too many re-measures on the MicroVu, which are Non Value Added activities to the final product for the customer. The aim is to decrease number of re-measures by implementing specific procedures of maintaining operation of MicroVu and realigning its parts.

Further Information on – What is a MicroVu? 

MicroVu measuring machine provide high precision dimensional measurements for quality control and inspection.

        

Source: Youtube https://www.youtube.com/watch?v=8Hz8mNKp_bc

Goal statement :

A Six Sigma project Gantt Chart will also help to ensure deadlines of each phase are achieved to complete all of the goals below.

 

Goals are SMART - Specific, Measurable, Attainable, Relevant, Time bound estimated for max 12 weeks.

1. Allocate specific training and support for the usage of MicroVu.
2. Reduce labour cost – Decrease of minimum 25%.
3. Saving projection up to €40,000/yr saving on labor.
4. Stabilize the process. Have define Operation Procedure for In-Process Measurement (MicroVu).

5. Time saving projection 20% of total number of measurements.
6. Reduction usage of quartz mandrel 33%.

Metric	Baseline	Goal	Blue Sky
Labour Cost	€16,0000 / yr	25% Reduction	30% Reduction
Time of Measurements	7800 Hours / yr	20% Reduction	30% Reduction
Quartz Mandrel Cost	€36,000 / yr	33% Reduction	66% Reduction
Financial Savings	Project Savings €51,880

Project Scope:

Project Scope is focusing on customers, theirs expectations and needs, also from the company point of view it is vital to improve manufacturing and minimalise waste (savings). The key factor in the scope is to establish CTQ's and theirs opportunity for improvement. When documenting project scope's all involved parties are required to be specific as possible in order to avoid scope creep. Also flow chart be be determined during the definig the project's scope.
Brainstorming Session will help to establish potential causes of the existing problem.