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REDUCE DEFECTS IN PACK PROCESS. ROOT CAUSE ANALYSIS. ENGAGE ASSOCIATES. RESULTS. IMPLEMENT CHANGE. AFTER. BEFORE. GOALS ACHIEVED. QUALITY IMPROVEMENT. COST REDUCTION. HAPPY CUSTOMERS. POKA YOKE. - PowerPoint PPT Presentation
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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
