All entries for Monday 14 November 2011

November 14, 2011

Applying DMAIC methodology

Airplane


Six Sigma Case Study....

What we learned today is how to apply DMAIC methodology and tools. Graeme (module tutor) gave us a task of making an airplane by assembling parts. Initially operations have been divided into seven parts then seven of us have to do their specific task of assembling parts of airplane other seven will observe the operation team regarding time and consistency one of us will cheek quality of product and that’s how we prepared 11 planes...

Our aim was to prepare 1 airplane in between 3 min 15 seconds to 3 min 45 seconds, because this is the customer tolerance level. and if we fail to do that that would affect profitability of the organisation.

What we learned from this case study is we recorded each step of the process, then we drawn a chart showing average time taken to complete each process, then we analyzed those processes we found that process two and four requires more time than other processes. Also some of the operators have to wait until others finish their job. We missed our target as we produced 11 planes but out of that we were able to make profit in only 4 planes.

Now we got new target with new strategies and new team will perform that task again to see the improvements. We have to reduce variation in the process by observing and understanding the process.

I also learned something about wastage. Before attending this case study my thinking about wastage is the only product wastage and product defect but today i came across several different types of wastage, like wastages in transport, rework (doing same work again), inventory, motion, overproduction etc. So whatI learned from this is we can think about type of wastages and then work on those wastages to improve process.

I think we all had fun today by assembling airplanes lets see tomorrow how we can do better..photo-2.jpg


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