November 14, 2011

Six Sigma Improvement Exercise

Today, we were introduced to the six sigma improvement excercise during our lectures. The task was to produce Meccano airplanes. Mecanno airplanes is basically an engineering toy which had a certain few steps in its production. We were required to produce them in a certain time period or else we were penalised both for early as well as late production. Certain operators were chosen who worked on the production line and others were there to study the process, make note of how the process could be improved and keep the time.

It really was a very interesting excercise. Although it was a very simple production we got a real insight as to how a manufacturing process works. It gave me a real time experience as to how different stages of production are interlinked and how important it is to have a good relation with each other. Just by observing the process I could see a lot of areas for improvement in the production. It was evident that there are unlimted oppurtunites for waste in this production. I could not even begin to think how closely the real manufacturing processes would be taught before implementing. It did give me a reason to believe that even if we observe a manufacturing process in reality, we are bound to notice a lot of areas for improvement. Today, was really a good learning point. Moreover, it was my first encounter with the six sigma. We are on our way to applying it in our excercise. We are at Stage 1 of the DMAIC cycle where we have define the process.

What was really interesting is that we are currently at 0 sigma where we produced 100% DPMO. So, the only way forward is upwards. From tomorrow we would countine with six sigma improvement process and hope to reach our targets. I am really looking forward to it and successfully complete my first six sigma project. It will be a great learning process and I am sure it will help me in understading the six sigma process much better than the literature.

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  1. 100% DPMO is really sad result. However, it is do a hard work. I try one by myself and find i take longer time than average for a single plane. Our operators and observers did really good job.
    Problems for us are 100% defect and lots of wastage and these two are priority which we should figure out. According PMI’s method, we should select one to resolve, isn’t it? I am no idea about and that’s my question as well. What do you think?? Do we work it out together or separate£¿

    15 Nov 2011, 07:55

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