Chronic Quality Problem Solving through Six Sigma

A leading multinational group mainly into designing, manufacturing, commissioning and servicing custom-engineered process equipment, modular skids and turnkey plant.Introduce operations excellence and structured scientific approach of Lean and six sigma for chronic problem solving by using advanced data analysis tools.
Poor quality and unsatisfied customers had driven staff morale to very low levels. The capability improvement through this project showcased the power of six sigma and enabled the top management to take notice of the Six sigma methodology and decided to implement an organizational initiative of six sigma
Chronic Quality problem solving through Six sigma

Client:

A leading multinational group mainly into designing, manufacturing, commissioning and servicing custom-engineered process equipment, modular skids and turnkey plant.
Challenge:

Introduce operations excellence and structured scientific approach of Lean and six sigma for chronic problem solving by using advanced data analysis tools.
Project:

To reduce the internal and external rejections for the defect ” tube expansion more than the spec. of 4-6%” Approach : Six Sigma DMAIC approach for problem solving
Activities:

Black belt Training of key personnel involved in the projects, Toll gate reviews at each stage and hands on guidance, coaching and mentoring for the project.
Results and financial returns:

:: Drastic reduction in Internal and external defects of “tube expansion “ resulting in Cost savings of $112500 per annum.
::Sigma value increased from dismal 0.5 to 3.2. Through the Use of higher statistical tools and DOE, Root causes identified and solutions implemented.
What makes this a “Lean Six Sigma” project?

:: Focus on reducing the number of chronic defects found by customers and internal defects.
::Intensive use of Input / process metrics and quantitative methods.
The Lean Six sigma toolkit:

Process mapping techniques, Process capability analysis and metrics, cause and effect analysis, Pareto analysis, Measurement system analysis hypothesis testing and regression analysis , design of experiments Statistical Process Control (SPC).
How did we engage people and drive change?

Poor quality and unsatisfied customers had driven staff morale to very low levels. The capability improvement through this project showcased the power of six sigma and enabled the top management to take notice of the Six sigma methodology and decided to implement an organizational initiative of six sigma.
Gazelles added value:

Extensive experience in Manufacturing Process Improvement initiatives and the ability to effectively teach and practically apply more advanced verification techniques for defect containment and elimination.

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