As the Six Sigma analyst you are required to use DMAIC on MC based on the in-house data that they have been generated (see EXCEL data ) starting with developing a Six Sigma Project Charter and making a business case to Management that your approach would improve their bottom line. Using the information given in the following memorandum.
Memorandum: Reducing computer system order filling times for MC.
To: Six Sigma Analyst
From: Board of Directors, MANATEY Computers (MC)
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After reviewing computer filling times for past three years (2012-2015), MC believes that corrective measures have to be taken to improve the company's bottomline and improve customer's satisfaction
- Project Leaders: Varun A./Matthew T. (Team Leaders)
- Team Members: Deepak C., Giri C. (Black Belts), Dheeraj G., Shiva K. (R&D Directors),
- Vaibhav K., Antonio, P. (Green Belts), Johnathan R. - Construction Engineer
- Stakeholders: Dinesh R. -Team Champion, Binoj R. - Production Director, Vinod R., Mohamed S. (Marketing and Sales Directors)
The business case can be rephrased as: Computer order fillings times reduction ad hoc exercises recently completed did not meet the requirements of customers/clients.
MC finance department estimates a budget overrun cost of $120 per unit for each day late (for extra inventory carrying costs, facility space for storage, internal tracking costs once production of a unit begins in the manufacturing department, and increased shipping costs for late orders). Based on a 28-day budget, they had 582 days of late order overruns in the past three months, equating to approximately $70k per quarter (or ~$280K annually).
These issues have created customer dissatisfaction and cost the company roughly $70k per quarter.
Preliminary Plan Target Date Actual Date
Start Date ?
DEFINE ?
MEASURE?
ANALYZE ?
IMPROVE ?
CONTROL ?
Safety Reviews ?
Completion Date ?
The data provided by MC include the following.
- The process map for MC computer systems order filling processes
- Historical (H) Order filling times data for 244 orders collected over the past three months with 28 days or less requirement.
- A more in-depth look at order filling times - Special fill times (S) - To better understand the sources of variations.
- Possible causes for late order deliveries
- A new and verified order filling times based on your analysis report back to the company (Verification)
Major Tools to be used:
Many Box plots
Many Pareto Charts
Many Cp capability histograms (you must understand the output from Cp analysis and check how that interfaces with your Box plots)
Deliverables.
1. A formal report due August 2, 2016 in a DMAIC Format (Hard Copy)
2. Oral Presentations - 5 Min. July 28.
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