Cycle Time Reduction Project: Enhancing Productivity at ABC Ltd.

1. DMAIC Project Name : Cycle time reduction. Project Owner : s.n. parmar,ajay kumar choudhari 1 9/29/2019

2. Overview Project Progress Overview Define Measure Analyze Improve Control Tollgates: Planned Completed 18/d05/2013 27/05/2013 05/06/2013 03/may/2013 18may/2013 XXXXXX 15/March/2010 mm/dd/yyyy mm/dd/yyyy mm/dd/yyyy C1. MSA on Xs C2. Improved Process Capability C3. Establish Control Plan I1. Screen for Vital Xs I2. Screen for vital Xs I3. Define Improved Process A1. Baseline Process A2. Performance Objective A3. Identify Drivers of Variation M1. CTQ Characteristics& Standards M2. Measurement System Analysis M3. Data Collection Steps: D1. Map Project D2. Approve Project Key Deliverables: • List of Customer(s) and Project CTQs • Team Charter • High Level Process Map (COPIS) • CAP Plan (Optional) • Preliminary CBA, if applicable • QFD / CTQ Tree • Operational definition, Specification limits, target, defect definition for Project Y(s) • Data Collection Plan • Measurement System Analysis • Baseline of Current Process Performance • Normality Test • Statistical Goal Statement for Project • List of Statistically Significant Xs • List of Vital Few Xs • Transfer Function(s) • Optimal Settings for Xs • Confirmation Runs/Results • Tolerances on Vital Few Xs • MSA Results on Xs • Post Improvement Capability • Statistical Confirmation of Improvements • Process Control Plan • Process Owner Signoff • Final CBA, if applicable • Basic Statistics • Histogram • Dot Plots • Box and Whisker Plots • Run Charts • Normality Testing • Continuous/Discrete Zst, Zlt • Benchmarking • Detailed Process Mapping • Moments of Truth • Nature of Work • Flow of Work • Fishbone • Hypothesis Testing • Regression Analysis • Other ______________ • Survey • Focus Groups • Interviews • ARMI, Stakeholder Analysis • In/Out of Frame • Threat vs. Opportunity Matrix • Other ______________ • DOE • Pugh Matrix • New Process Mapping • FMEA on new process • Process Modeling / Simulation • Other ______________ • Continuous Gauge R&R • Discrete Gauge R&R • Control Charts • Hypothesis Testing • CAP Plan • Control Plan • Other ______________ • Data Collection Plan • Continuous Gage R&R • Attribute Gage R&R • Sample Size Calculator • Other ______________ Tools:

3. Define • Blank • Project Charter • Terms and Acronyms Used • ARMI & Communication Plan/Why not RASIC • SIPOC • Process Map

4. Define

5. Project Charter Define In Scope:Quality control. Business Case:ABC Ltd. is the largest optical media manufacturer in the world. We are also manufacturer photo voltaic cell. We make CD /DVD at automation line from raw material (polycarbonate) to final disc in which use of polycarbonate, dye, ml, bonding glue ,silver etc. First time raw material (polycarbonate ) feeding in moulding m/c after we receive blank substrate disc than disc going for dye coating than coated disc go to dryer for 30 minutes at 90 degree farnhite temp. after than silver coating on the disc for reflectivity . And take one blank substrate disc bonding on dye coated disc. Out of Scope:All the other process of this organization. . High Level Project Plan Problem Statement: Last two months data show that average cycle time 405 second instead of 300 second which is 53% productivity loss from our target and its effect on our customer and profit. . Goal Statement: I will be reduc the cycle time 405 to 300 second on dated 15 th june 2013.

6. Terms and Acronyms Used Define Definitions:

7. ARMI & Communication Plan Define ARMIWorksheet CommunicationPlan • When Populating the Stakeholder, consider the ARMI: • A= Approver of team decisions • R= Resource or subject matter expert (ad hoc) • M= Member of team • I= Interested Party who will need to be kept informed

8. SIPOC Define

9. Measure • Data Collection Plan • Measurement System Analysis • Process Capability

10. Data Collection Plan Measure Mode of collecting Data

11. Measurement System Analysis Measure

12. Measurement System Analysis Measure

13. Process Capability Measure since P value <0.05 hence it significant effect on population. Data is not normal so that the process Capability is not require so DPMO calculate.

14. Measure DPMO Dpmo = defect per oportunity * 1000000 =0.5349264*1000000 = 5349264 Dpo = total no of defect /total opportunity = 291/544 = 0.5349264 Sigma level =1.40

15. Analyse • DCP for Potential Xs • Identify Potential Xs • DCP for Potential Xs • Basic Analysis for Project Y • Checking for Impact of ...... on Y • Hypothesis Summary • MSA results of Impacting Factors

16. Identify Potential Xs Analyse Factors identified through brainstorming

17. Basic Analysis of Project Y Analyse Randomness & Shape Study Normality Study Since p -value is less than 0.05, hence the data is not normal.

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