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Lean Six Sigma Final Project

Final class project for the Lean Six Sigma program at U of T (October 2014)
by

Cuthbert Demello

on 1 November 2014

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Transcript of Lean Six Sigma Final Project

D M A I C
The High Flyers
Average patient wait time
until they see their doctor
New Age
Aircrafts
D
efine
-Project Background
-Project Charter
-SIPOC
-Process Map
M
easure
- MSA
- Data Collection Plan
- Process Capability
-Fishbone
-5 whys
-Pareto
-Hypothesis
-Correlation
Project Charter 1/3
Fishbone
present
A
nalyze
I
mprove
C
ontrol
Project Background
New Age Aircraft (NAA)
is a company in the children’s toy industry.
They have released a new product line which engages children in making paper airplanes, drawing a picture about each airport and learn about various places in the world as they fly the planes to different airports.

Why is it so hard to land the plane on the airport?!

Problem Statement:
During the last 6 months kids complained difficulties with making the airplane fly straight and to land on the airports. With this issue NAA sales are not generating as expected and could essentially end the production and loose the anticipated 5 million of revenue annually.

Goal and Objectives:
To increase flights landing at the airports within 12 inches radius by 80%.
Improve launcher positioning consistency to 100%

Project Scope:
Launcher positioning
Airplane design
Refined scope: Launcher positioning which have the largest negative deviation.

Timeline:
Project is estimated to be completed in 4 weeks

CTQ = Landing distance within 12 inches airport for at least 80% of flights


Primary Metric/ Baseline:
If it lands within the target area

Secondary Metric/ Baseline:
Actual distance of plane from airport

Project Benefit:
Potential revenue will be realized as a result of satisfied customers
(Estimated at 20% increase)

Soft Benefit:
Happier children, easier to play the game
(Estimated at 50% increase)
Project Charter 2/3
Project Charter 3/3
We need people!

RACI:
SIPOC
MSA
Gage R&R
% of Contribution is less than 1% (World Class)
Operators are precise and consistent
% of Study variation is less than 10%
The number is larger than 4, so measuring system was small enough

MSA is good!
Data Collection Plan
Graphical Summary
The distribution of the distance from the target is multimodal. Modes are originating because of the wing-span.

Normality Test
Control Charts
The process is within control for a particular plane design (Showing only the plane with wing-span of 8 cm.

Data Normality Test
The distribution of the distance from the target is not normal. Distribution for a plane with a particular wing-span is normal

Capability Analysis

Customer Specification: Plane flies smoothly and land within 12’’ radius of The airport which is 10 Feet away.

Process Performance
Process Capability
We have 3 different design (wing span)
3 members throw with 3 different techniques (height)
Each member measure the distance of the landing point to the airport for each landing two times (trial #1 to 5);
Total of 135 samples collected!

Zahid entered the announced data into the excel sheet (Capability A. Data, index)

The same measuring tape was used for all the measurements.

Even for the best plane, current Z-value is 0.05 (long-term), having 52% target success (<80% = goal).

Capability is bad!
Correlation
Pareto
5 Whys
Q: Why Plane doesn’t land on the target airport?
A: The plane doesn’t travel all the way.

Q: Why Plane doesn’t travel all the way?
A: May be the force opposing the flight is too large?

Q: Why can’t you put more force?
A: Then the plane deviates from its direction.

Q: Why can’t you reduce the opposing force then?
A: I have to reduce dragging force and for that I have to change the design.

Q: Why can’t you change the plane design?
A: I can. Then I have to change the wing span to reduce surface area.

If possible, let’s investigate its effect then.

Found out standard deviation contribution from each input element using Gauge R&R.

Wing-span
Height of the through
Operator
Trial




Hypothesis Test
What's the real cause then?!
Narrower wings allowed us closer to the target.
Throwing from higher level was helpful for planes with wider wings (more drag).
For plane with 8 cm wing span, it was better to through from lower height.
Otherwise it went too far resulting greater error…



Measuring distance from the throwing spot can further proof the theory!
Plane which has a correlation with the distance from the target.

QUESTION: Will plane with narrower wing-span be better?

Answer: No. Why?




Summary


Plane with wingspan of 8 cm performed the best.

Throwing plane while kneeling resulted best performance.

Reducing variation due to other process parameters can be attempted later on.
- Brainstorming
- New Process Map
- Baseline vs Improved
- New Capability Analysis
-Reaction Plan
-Control Charts
(before and after)
Brainstorming Session
TOP 3
New Process Map
Improved Capability Analysis
Normality Test
I-MR Chart: Throwing the plane while kneeling
Reaction Plan
Control charts (before and after)
Control Conclusion
The Control Plan system included here assures that improvements we established will not deteriorate once the improved process is executed.
We standardized the kneel requirement by providing a mat with a label “kneel before you launch” 3 ft from the ground within the product itself.
Correct wing measurement was reinforced by adding a visual control (Kanban)
We eliminated the major and common causes that are major contributors to the process variability -
poor design and normal wear, and tear and broken parts.
SOP and video were also supplied in the product which were not supplied in the initial launch of the product

Diego Delgado
Cuthbert Demello
Kamarah Francis
Julio Frignani
Ederlyn Pinera
Zahidur Rahim
Mahtab Riahi

The High Flyers
Any
?'s
Thank
You
Final Thoughts
High-level Process
Full transcript