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Lean Six Sigma Group Free Project Case Study Overviews http://www.linkedin.com/groups/Lean-Six-Sigma-37987 Sponsored by the International Standard for Lean Six Sigma, e-Zsigma http://www.e-zsigma.com, IQPC, and PEX Network. Please contact Lean Six Sigma Master Black Belt, Steven Bonacorsi, Owner of the Lean Six Sigma Group to have your project case studies to be added to the Lean Six Sigma Group Library. Steve Bonacorsi [email protected]
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Project Leader:
Start Date:
Software Store:
Special
Applications GEAE Lynn Account
George Harris
Customer Engineer
September 27, 2002 Master Black Belt: Steven Bonacorsi
Business Problem & Impact GEAE shop floor end users experience unnecessary downtime during system replacement, due to incomplete configuration and uninstalled required applications . One shop floor workstation can be down for days as multiple help desk tickets are required to get the system 100% functional.
Six Sigma in Action Software: Special Applications
Results/Benefits Mean cycle time decreased from >59 minutes to <33 minutes while Sigma value increased from .02 to 2.99. This results in an expected customer indirect savings >$7,600 (annually)
Measure & Analyze Data Collection: Cycle time to complete 1 shop floor deployment was measured. Any deployment taking >60 minutes was listed as a defect Root Causes: There is no process or documentation detailing the Shop Floor Special Application Installation and Configuration MSA Results: An MSA was not performed during Measure for the following reasons: 1.Cost in labor to complete a measure MSA was to great to complete. 2. GE ITS did not control the process used in baseline 3. Infrequent cases also made MSA too costly.
Customer Profile – 8,000 seat Aircraft Engines Manufacturing Company
Improve & Control A Pugh Matrix was used to determine the best possible solution. Having GEITS technicians install special applications and configure shop floor systems prior to deployment, had the greatest positive impact on cycle time. A new shop floor deployment process was developed and implemented in March 2003, with training sessions and documentation provided to deployment techs prior to rollout. All data points collected were within the 60 minute specification limit.
Process Capability – Before
Process Capability – After
15010050
15
10
5
0
USLT
Total Cycle Time
Fre
quency
Sigma (ZST):
1.52
Sigma (ZLT):
0.02
60555045403530252015
8
7
6
5
4
3
2
1
0
USLT
Deploy Time
Fre
quency
Sigma (ZST):
2.99
Sigma (ZLT):
1.49
An ACFC Project with an Expected Customer of >$7,600 annually!
