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CASE STUDY Manufacturing Organization

. . A Review of the Deliverables:. These are the guideline deliverables. You may want to refine for your project.Also, remember to refine your Charter as you progress through your project.. DMAIC Steps. Phase. Deliverables. Define. SIPOCCustomers and CTQs establishedProblem Statement, Business

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CASE STUDY Manufacturing Organization

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    1. CASE STUDY Manufacturing Organization Project Name: Wastage Reduction in Manufacturing process of XYZ Ltd Process : Manufacturing Green Belt : Mr ABC

    2. DMAIC Steps

    3. Define Phase- • Project Charter • Business Case • SIPOC • Voice of Customer (VOC) • Critical To Quality (CTQ)

    4. DMAIC Project Charter

    5. Define the problem statement- Project charter Background/problem description: Current process wastage is very high as close to 20%hence process becomes sub-optimal and high resource is required to do inspection of final output. Project objective/goal: High wastage leads to pressure on COGS. Hence it is essential to reduce the wastage to less than 10%. Project deliverables: identify the reduce the High wastage leads to pressure on COGS.

    6. BUSSINESS CASE AND IMPACT- • XYZ is the first product XYZ Ltd, India is exporting to US market • This product is very critical as it is new product in the Kids range in US • Based on success of this product J&J India can get other new products from US and from other franchises like Neutrogena • The process of pouching soap in to bi-layered tredegar film(aperatured plastic film) is developed by XYZ Ltd India team • Current process wastage is very high as close to 20% hence process becomes sub-optimal and high resource is required to do inspection of final output • Due to limitation in manual checking a rejected soap can go to the market and can lead to serious market complaint • High wastage leads to pressure on COGS • Tredegar film contributes around 18% to total COGS Hence it is essential to reduce the wastage to less than 10% • Business Impact – – USD 10101 or Rs. 505,050 PER ANNUM

    7. High Level Improvement Timeline

    8. SIPOC

    9. .

    10. .

    11. voice of Customer by Kano Model

    12. Analyze Phase- Multi-Vari Analysis – Operator – Shift – Machine Hypothesis testing using ANOVA Cause & Effect diagram – Improper sealing – Uneven cutting

    13. Analyze Phase- Multi-vari analysis out put. – Shift is having slight impact on rejection. In the A shift rejection is less which is mainly due to more supervision. – In case of operator unskilled operator showed high amount of wastage – Machine 3 & 4 showed less wastage, so concentrate on machine no. 2

    14. Identify the y to be improved- Y= reduce the High wastage leads to pressure on COGS.

    15. Fish Bone Diagram/Cause & Effect/Ishikawa Diagram

    16. Cause & Effect analysis:-

    17. .

    18. Fish Bone Diagram/Cause & Effect/Ishikawa Diagram

    19. .

    20. . • Improper sealing and uneven cutting are two major reasons for generating high amount of wastage. • Out timing was noticed to be main cause of shifting the position of soap in sealing and cutting station • Group discussed to concentrate on reasons for out timing

    21. Cause & effect analysis-

    22. . Innovative Improvement- • Solution prioritization matrix • FMEA of defects • Cost Benefit Analysis

    23. Control Phase- Process capability & sigma – Process yield improves from 61% to 88% – Sigma improves from 1.9 to 2.7 • System modification – Tredegar machine maintenance SOP revised to include schedule for replacing soap feed conveyor links to quarterly basis – Suction system implemented for trim collection • Key Learning's – Use of PE methodology to systematically analyze the process which gives opportunity for process improvements

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