1 of 30

Presentation Template: Instructor Comments

  • The following template presents a guideline for preparing a Six Sigma DMAIC presentation. An effective presentation should be similar in format & length (~20-32 slides) but will obviously vary based on data available, findings and presentation style.
  • NOTES:
    • Feel free to use this PowerPoint template to set up your presentation format style
    • The italic text in these template slides presents examples from a sample

​

1

2 of 30

TITLE �DESCRIBE TOPIC AND PURPOSE�(ENTER DATE OF REPORT)

Name, Title of Presenter

Name, Title of Presenter

Department/Organization of Presenters

3 of 30

HEAD LAMP MANUFACTURING �MOLD CHANGEOVER REDUCTION�(NOTE: THIS IS A SAMPLE PROJECT PRESENTATION – �SLIDES/TOOLS WILL VARY BY PROJECT)

Adapted from project by Don Lynch,

Univ. of Michigan

4 of 30

Executive Overview (Optional: 1-2 slides)

  • Project Summary - Briefly describe the project, include:
    • Problem statement
    • Current performance level
    • Target performance level
    • Summary of Analysis, including key findings and conclusions
    • Recommendations

​

Note: By including a summary of your main conclusions and recommendations in the overview, you give the audience a viewpoint from which to interpret the data you present.

​

4

5 of 30

Define Phase (1-3 slides)

  • Define the problem
    • Describe the problem, including any needed background on the process or product studied
    • Identify the metric or key performance indicator (KPI) to improve and any performance goals or requirements
    • Include the potential impact of the improvement opportunity
    • Identify key project team members and project stakeholders
  • Some possible tools:
    • Project Charter Information (Problem Statement, 5W2H Approach, Goal Statement, Scope)
    • Process Map (SIPOC Diagram, Value Stream Map (VSM), Swim lane Diagram)
    • Pareto Chart (May be used to help support why project was chosen)

​

Note: See report template, course notes, or other resources for more details

5

D

M

A

I

C

6 of 30

Project Metrics or Key Performance Indicators (KPI)

  • All projects must have a clear metric (e.g., KPI) for quantitative assessment from current state (baseline) to end of project
  • Examples of Metrics or KPI’s used in DMAIC Projects:
    • Quality Measures (Critical-to-Quality)
      • External: Customer satisfaction ratings, customer complaints, warranty
      • Internal: Yield, Rework, Scrap, PPM Defective, DPMO, Process Capability Indices, etc.
    • Time/Delivery Measures (Critical-to-Time or Delivery)
      • Process time, Lead time, Turnaround Time, % On-Time, Downtime, % VAT, etc.
    • Cost Measures (Critical-to-Cost)
      • Product/service cost, raw material costs, inventory costs, revenue/profit margin, etc.

​

6

7 of 30

Example: Define Phase - Mold Changeover Study�(Setup Time Reduction Project)

Problem Statement:

Over the past year, injecting molding department has experienced an excessive number of mold changes with high mold changeover time per change resulting in excess labor hours vs. budget and inventory control issues. This has resulted in scheduling problems with headlamp assembly. This has been a chronic problem and is costing over $150K/year.

​

Scope:

Focus on reducing the number of changeovers and time per changeover for the 34 mold machines in the headlamp lens molding department.

​

Improvement Goal:

Eliminate mold changeovers taking longer than 2.5 hours.

7

D

M

A

I

C

8 of 30

Example: Head Lamp Assembly�Value Stream Map (VSM)

8

Setup Time

Reduction

Mold Department

(changeover)

9 of 30

Example: Potential Projected Savings for Changeover �(Selling the project business case)

  • Currently, lose ~$165K in production hours due to excess changeover time

9

D

M

A

I

C

10 of 30

Measure Phase: �Current State Performance (1-4 slides)

  • Summary Current State Performance for Metric or KPI
    • KPI – Key Performance Indicator
  • Possible Tools/Data Analysis to include:
    • Process Map (if not already done, include process map, often with more details)
    • Measurement System Analysis (MSA) and/or Validation
    • Process Capability Analysis (e.g., Yield, PPM Defective, DPMO)
      • Include descriptive statistics where appropriate (E.g., Mean, Standard Deviation)
      • Include graphical analysis tools where appropriate (E.g., Histogram)
    • Process Stability Analysis/Control Charts
    • Rolled (Throughput) Yield (e.g., if seeking to improve yield over multiple process steps)

10

D

M

A

I

C

11 of 30

Example: Process Map - Mold Changeover Process

  • Current State Map - Changeover Process
    • Note: May include in Define Phase

​

11

‘Cannot improve a process until you agree on what it is’

Changeover Process

D

M

A

I

C

12 of 30

Example: Measurement System Validation

  • Measurement system was evaluated by sampling 30 changeovers and comparing ‘system’ results to ‘actual’ timed results
    • Note: Projects may not have Measurement Systems Analysis or Validation

​

12

P-Value = 0.456

No significant difference by group

​

Measurement System Accepted

D

M

A

I

C

13 of 30

Example: Process Stability Analysis (Consistency)

  • Appear to have a Chronic Problem (while changeover times are not acceptable, changeover process is stable or consistent)

13

D

M

A

I

C

14 of 30

Example: Process Capability - Mold Changeover Time

  • Current State: Average changeover time is 3.5 hours with standard deviation =1.1
  • PPM Defective: ~813,000 (or % Defective = 81.37%, Yield = 18.63%)
    • Have both Mean and Variation Problem with Bi-Modal Distribution

14

Histogram – Changeover Time

D

M

A

I

C

15 of 30

Analyze Phase

  • Identify causes of defects and main sources of variation
  • Possible analysis tools include:
    • Qualitative Analysis: Cause-Effect Diagram, P-Diagram, Diagnostic Tree, etc.
    • Quantitative/Root Cause Analysis:
      • Graphical Analysis (e.g., Pareto, Stratification analysis: Multiple Box plot, Interval Plots)
      • Scatter Plots/Correlation Studies/Regression Analysis
      • Hypothesis Test Results
      • Experimental design results (Tip: Present most results using simple graphics/tables – include full statistical analysis output from software in an appendix.)
    • See course notes for more examples

15

D

M

A

I

C

16 of 30

Example: Qualitative Analysis - Cause-Effect Diagram

16

Or show using P-Diagram

D

M

A

I

C

17 of 30

Example: Quantitative Data Analysis �Mold Changeover Variables to Study

  • Mold Case Study - Factors or Variables to Study
    • Differences by Mold Machines (Machine ID)
    • Shift-Shift Differences
    • Changeover time by specific changeover tasks

​

17

D

M

A

I

C

18 of 30

Example: Stratification Analysis by Machine ID

  • Findings: Changeovers are not dependent on individual Machine ID
    • No statistically significant difference (based on ANOVA Mean test p-value)

18

D

M

A

I

C

19 of 30

Example: Stratification Analysis - Changeover by Shift

Analysis By Shift: No Difference By shift (confidence intervals overlap)

19

D

M

A

I

C

20 of 30

Example: Pareto Analysis�(Top 2 Accounting for 50% of Lost Time)

20

Top two factors:

Waiting time for carts - 28%

Heating process - 21%

D

M

A

I

C

21 of 30

Example: Effect of Changeover Cart Availability

  • Top causal factor, wait for cart
    • If purchase another die change cart, there is a potential to reduce average changeover time from 4.81 to 2.87 (cart effect alone)

​

21

Cart Available: Yes=1

D

M

A

I

C

22 of 30

Example: Analyze Phase – Summary of Findings

  • Top two causal factors (waiting for changeover cart and heating process) accounted for ~40-50% of total time or an average of 1.3 hours per changeover
  • Of the setup tasks, half of the actions could be completed with prior mold still running (external)
  • Other actions (and almost half of the average total time) required mold to be down when performing

​

22

D

M

A

I

C

23 of 30

Improve Phase

  • Identify Alternative Solutions Considered
  • Identify specific solution(s) to achieve performance goals:
    • Specify criteria for selecting solution
    • Present conclusions
    • Identify chosen solution(s)
  • Include short-term verification (e.g., pilot) of recommended solution using:
    • Follow-up PPM/DPMO analysis
    • Follow-up Process Capability Analysis
    • Follow-up Control Charts to demonstrate Process Stability post recommendations
    • Note: These may also be included for long-term verification post DMAIC project

23

D

M

A

I

C

24 of 30

Some Possible Improve Phase Countermeasures

  • Countermeasures often may be classified under one of the following
    1. Improve Workplace Organization (e.g., via ‘5S Process’)
    2. Improve Training
    3. Implement New Standardized Work Practice
    4. Redesign/Improve Process Flow
      • Reduce batch sizes/improve setup
      • Change Process Layout (e.g., Cellular Teaming) or Workflow
      • Re-balance workload across operators (operations)
    5. Change (Optimize) a Process Setting (e.g., staffing plan)
    6. Implement Quality at the Source (‘Source Inspection’)
      • Error Proofing (‘Poka-Yoke’)
      • Self-check or Successive check system
    7. Install New Process Monitoring Systems
      • Visual Controls & Management
      • Implement new data collection/monitoring system

24

D

M

A

I

C

25 of 30

Example: Improve Phase Recommendations

  • Mold Changeover Study: Improvements implemented in 3 phases
    • Phase I – Address top two issues: heating process and wait for cart
      • Scheduling of mold changes was changed to coincide with breaks
        • Time for heating was hypothesized to go from 0.62 to 0.12 hours
      • Optimum # of carts calculated, and additional cart was purchased
        • Time waiting for carts was hypothesized to go to zero
    • Phase II – Take more actions external to mold changeover time
    • Phase III – Streamline internal actions

​

25

D

M

A

I

C

26 of 30

Example: Improve Phase – Verification

  • Reduction over time by phase - Phase I and II had greatest impact

​

26

D

M

A

I

C

27 of 30

Control Phase

  • Identify a control plan and/or process control mechanisms to ensure system will continue to perform
  • Some tools or examples to Include:
    • Process Control Plan
    • Process Monitoring/Tracking system
    • Error Proofing mechanisms

​

27

D

M

A

I

C

28 of 30

Example: Control Phase – Mold Changeover

  • Case Study Recommendations:
    • Phase 1 – Address the top factors (cart and heat process)
      • Revise mold changeover process to heat up the system during lunch when possible (i.e., adopt new standardized work practice)
      • Added process monitoring chart for changeover time
    • Phase 2 – Take external actions outside of mold changeover
      • Assigned new labor standards for changeover team
      • Changed control plan/standardize work for mold changeover process to convert external actions to occur outside of press
      • Added error proofing devices to simplify setup process
      • Provided updated instructions/training to team for new process

​

28

D

M

A

I

C

29 of 30

Post DMAIC – Changeover Verification Study

  • Ran study of 50 changeovers with new process
  • Based on these, projected Actual Savings: ~$200K

​

29

30 of 30

Summary

  • Briefly recap project
    • Problem statement
    • Process/approach followed to reach solution(s)
    • Conclusions
    • Recommended solution(s)
    • Potential benefit
  • Briefly explain next steps
    • Implementation schedule (if not already done)
    • Actions to be taken
    • Persons responsible for future actions

​

30