REDUCE DEFECTS IN PACK PROCESS

Ship:W

eightO

utOfTo

leran

ce

Scanner1

Failu

re

Ship:M

issingP

ackag

eData

GTS:Pro

cessW

ithMan

ualSlam

Ship:Pro

blemSo

lvingC

ondition

CustomOrU

nknownBoxO

nSlamLin

e

Ship:Alre

adyP

roces

sedCondition

Pack:FF

PValidato

r

MissingB

oxConfigu

ration

UnknownSh

ipmentID

Ship:NonSh

ippableC

ondition

NeedsG

iftWrap

MissingS

hinglesC

onfigurati

on

Pack:FR

ACSVali

dator

Pack:Se

rialNumberV

alidato

r0

20000

40000

60000

80000

100000

120000

140000

0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

55%

80.47%86.84% 91.34% 94.46% 100.00%

Pareto Analysis of Slam Kickouts from January to June 2013

Count of KO Reason Cumulative % of Total KickoutsKickout reason

Num

ber o

f Kick

outs

Cum

ulati

ve %

of T

otal

KO

Jun Week 1

Jun Week 2

Jun Week 3

Jun Week 4

Jul Week 1

Jul Week 2

Jul Week 3

Jul Week 4

Aug Week 1

Aug Week 2

0

100

200

300

400

500

600

0.00%

0.05%

0.10%

0.15%

0.20%

0.25%

488517

441

348

247266

342318

244

229

0.21%0.22%

0.20%

0.16%

0.12% 0.13%

0.15%0.14%

0.10% 0.10%

Flats Line Missing Package Data Weekly Count for two months

Flats Line Missing Package Data Weekly Count Defect % per total volume

Miss

ing

Pack

age

Data

Kick

out C

ount

Jun Week 1

Jun Week 2

Jun Week 3

Jun Week 4

Jul Week 1

Jul Week 2

Jul Week 3

Jul Week 4

Aug Week 1

Aug Week 2

0

200

400

600

800

1000

1200

-0.05%

0.05%

0.15%

0.25%

0.35%

0.45%

0.55%

977904

603

1094

433347

394

265 270 254

0.42%0.39%

0.27%

0.50%

0.21%

0.17% 0.17%

0.12% 0.11% 0.11%

Flats Line Scanner1 Failures Weekly Count for two months

Flats Line Scanner1 Failure Weekly Count Defect % per volume

Week

Scan

ner1

Kick

out C

ount

Defe

ct %

per

vol

ume

Jun Week 1 Jun Week 2 Jun Week 3 Jun Week 4 Jul Week 1 Jul Week 2 Jul Week 3 Jul Week 4 Aug Week 1 Aug Week 20

1000

2000

3000

4000

5000

6000

70006300 6126

4627

6608

33382918

3239

25612123 2030

Flats Line(Scanner1 and Missing Package Data) Weekly Average DPMO for two months

Flats Line(Scanner1 and Missing Package Data) Average DPMO

Week

Aver

age

DPM

O

REDUCE DEFECTS IN PACK PROCESS

ROOT CAUSE ANALYSIS

BEFORE AFTER

ENGAGE ASSOCIATES

RESULTS

HAPPY CUSTOMERS

QUALITY IMPROVEMENTCOST REDUCTION

GOALS ACHIEVED

POKA YOKE

IMPLEMENT CHANGE