Six sigma green belt - catapult project

Group # 1:

Six Sigma Project:Katapult

Instructor: Jay HamadeCourse: MSE 618

Date: May 7, 2008

Mohammed Albaqmi

Faisal Alkahtani

Yuriy Lozovskiy

Cristina Salajan

Nicola Sandoli

Khaled Alamahasin

Waleed Altwaijri

1

D M A I CD M A I CSix Sigma Project: Katapult

2

D M A I CDAssembly process

3

D M A I CDProblem Statement

Customers from Los Angeles Area have been

complaining about Katapult throwing distance

(current < 135 inches) beginning with September 2007.

Complaints have increased by 15% compared with

previous quarter according to the Customer Service

Department report

WhereWhat When Extent How do we know

4

D M A I CD

Capability of hitting a target: 185 incReduce process variability: 20 inc

Reduce complains about Katapult set up procedure by 10% (from 15% to 5%) by the end of the year 2008.

Increase Katapult revenues by $138,000 by the end of the year 2008.

Objectives

5

D M A I CDSIPOC

Suppliers• A Wood

Expression Inc• Automoblox• Bajo Toys USA

Inputs• Man Power• Specifications• Material• Minitab

Process

Outputs• Katapult

Optimum Set Up

Customers• Marketing

Department• Final Customers

Assembly Holding cup on Bracing

Arm

Assembly Bracing

Arm on the Base

Select rubber band

height on Bracing

Arm

Select Angle

Select rubber band

height on throwing

arm

Select Ball

6

D M A I CDVoice of the Customers (VoC)

Customers• Marketing Department• Final Customers

Data• Reactive

• # of Complains # of Returns• Proactive

• Surveys Sale Benchmarking

CTQs• Provide easy assembly instructions• Determine the Katapult configuration that

meet the expected target

7

D M A I CD MProcess Map

8

D M A I CD MMetrics

Height 31 inches

Primary Metric:

• The distance where the ball hits the ground.

Secondary Metric:

• Height from where the Katapult is placed

Distance

10

D M A I CD MGage R&R

P a r t- to - P a r tR e p r o dR e p e a tG a g e R & R

1 0 0

5 0

0

Perc

ent

% C o n t r ib u t io n% S t u d y V a r

1 0

5

0

Sam

ple

Rang

e

_R = 4 . 5 1

U C L = 9 . 0 4

L C L = 0

F a s i a l K h a l e d M o h a m m e d

1 8 0

1 6 0

1 4 0Sam

ple

Mea

n

__X = 1 5 9 . 4 4U C L = 1 6 1 . 6 2L C L = 1 5 7 . 2 6

F a s i a l K h a l e d M o h a m m e d

987654321

1 8 0

1 6 0

1 4 0

Part

M o h a m m e dK h a l e dF a s i a l

1 8 0

1 6 0

1 4 0

Operator

987654321

1 8 0

1 6 0

1 4 0

Part

Aver

age F a s ia l

K h a le dM o h a m m e d

O p e r a t o r

Com ponents of Varia tion

R Chart by Ope rator

Xbar Chart by Operator

Measure by Part

Measure by Operator

Opera tor * Part I nteraction

Gage R&R (ANOVA) for Measure

Gage R&R (ANOVA) for Measure

11

D M A I CD M

1 9 01 8 01 7 01 6 01 5 01 4 01 3 0

L S L T a r g e t U S L

Process Capability of measureCalculations Based on Weibull Distribution Model

Process CapabilityWeibull

142140138136134132130

9 9

9 59 0

8 07 06 05 04 03 02 0

1 05

1

measure

Perc

ent

Probability Plot of measureNormal

Probability Plot

Process Capability Analysis

142140138136134132130

9 9

9 59 0

8 07 06 05 04 03 02 0

1 05

1

measure

Perc

ent

M e a n 1 3 5 . 5S tD e v 2 . 2 7 1N 5 0A D 1 . 4 7 2P - V a lu e < 0 . 0 0 5

Probability Plot of measureNormal

1 9 01 8 01 7 01 6 01 5 01 4 01 3 0


P p 0 . 9 4P P L -2 . 5 7P P U 9 . 9 2P p k -2 . 5 7

O v e ra ll C a p a b ility


1 9 01 8 01 7 01 6 01 5 01 4 01 3 0


LS L 1 7 5T a rg e t 1 8 5U S L 1 9 5S a m p le M e a n 1 3 5 . 5S a m p le N 5 0S h a p e 5 2 . 3 7 7 3S ca le 1 3 6 . 6 9 6

P ro ce ss D a ta


1 9 01 8 01 7 01 6 01 5 01 4 01 3 0


P P M < LS L 1 0 0 0 0 0 0 . 0 0P P M > U S L 0 . 0 0P P M T o ta l 1 0 0 0 0 0 0 . 0 0

O b se rv e d P e rfo rm a n ce


P-value < 0.05

NOT Normal

Weibull distrib.

12

D M A I CD M AFishbone Diagram

THROWING DISTANCE

WOOD QUALITYRUBBER QUALITY

ARM WEIGHTARM DESIGN

BALL PHYSICAL CHARACTERISTICS

RUBBER BAND ON BRACING ARMRUBBER BAND ON THROWING ARM

ANGLE SELECTIONBALL SELECTION

HOLDING CUP ASSEMBLY

PROCESS INSTRUCTIONMANUFACTURING

OPERATORS

AIRFLOWALTITUDE

TEMPERATUREHUMIDITY

INDOORS

ENVIRONMENTMANPOWER

METHODMATERIALS

13

D M A I CD M A

1

Assembly Holding Cup on Throwing Arm

Tools 0 0 2 1 1 1 1 1 1 1 1 1 862 Operator 5 10 4 0 0 0 0 0 4 6 0 0 1693 Assembly instructions 8 0 7 5 4 4 5 4 1 1 1 1 3054 Nut and Bolt 5 10 4 0 0 0 0 0 4 6 0 0 1695 Cup 0 0 2 9 2 2 2 2 2 2 2 2 2196 Throwing Arm 8 0 6 4 4 6 5 1 1 1 3 3 3267

Assembly Arm on the Base

Tools 5 10 4 0 0 0 0 0 4 6 0 0 1698 Operator 0 0 4 8 3 2 2 9 2 2 2 1 2659 Assembly instructions 0 0 2 1 1 1 1 1 1 1 1 1 86

10 Assembled Throwing Arm 2 3 2 8 3 2 2 9 2 2 3 2 297

11 Nuts and Bolts 1 2 2 5 1 2 2 9 2 2 9 2 30512 Base 0 0 0 0 0 0 0 0 0 0 0 0 013 Bracing Arm 0 0 0 0 0 0 0 0 0 0 0 0 0

14

Select Rubber Band Height on Throwing /Bracing Arm

Assembly instructions 0 0 4 8 4 2 2 2 2 9 2 2 28215 Operator 5 10 4 0 0 0 0 0 4 6 0 0 16916 Assembled Catapult 0 0 4 8 3 2 2 9 2 2 2 1 26517 Operator 0 0 2 1 1 1 1 1 1 1 1 1 8618 Assembly instructions 0 0 5 2 3 2 2 9 2 2 3 20919 Assembled Catapult 0 0 2 9 2 2 2 2 2 2 2 2 21920 Bracing Pin 1 0 6 10 5 1 10 3 1 9 7 1 442

21 Throwing Pin 10 1 6 3 6 8 10 0 0 0 7 1 417

22

Select Throwing Angle

Assembly instructions 0 0 1 2 1 1 1 1 1 1 1 1 8723 Operator 0 0 2 2 2 2 2 2 0 0 1 2 12624 Assembled Catapult 0 0 2 2 2 2 2 2 0 0 1 2 12625 Angle Pin 10 1 7 9 6 9 10 0 0 0 8 1 49726

Setup

Assembly instructions 3 0 2 1 1 2 2 1 2 1 1 1 12327 Operator 0 0 2 2 1 2 3 1 2 1 1 2 13728 Assembled Catapult 5 0 2 2 2 2 3 2 2 3 2 7 24729 Balls 10 0 4 8 3 3 10 7 4 6 2 1 42330 Rubber Band 1 0 2 1 1 2 2 1 2 2 1 3 139

TOTAL 395 282 768 999 434 488 840 432 232 450 630 440 0 0 0

Cause and Effect Matrix

Rating of Importance to Customer 5 6 8 9 7 8 10 6 4 6 10 10

Process Step 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Design

Color

Price

Useful Life

Maintenance

Usage

Distance

Weight

Environmental Standard

Materials

Safety

Delivery Time Total

Process Step Process Input

14

D M A I CD M AFailure Mode Effect Analysis

Process/Product: Potential Failure Modes and Effects Analysis (FMEA) Process or Product Name:

Katapult Responsible:

Faisal Prepared by:

Faisal Waleed

FMEA Date:(Orig.) March 23 2008(Rev.) March 31 2008

Process Step/Input Potential Failure Mode

Potential Failure Effects

SEV

Potential Causes

OCC

Current Controls

DET RPN Actions Recommended Responsible Actions

Taken SEV OCC DET RPNPrevent Detect

Angle selectionInappropriate angle selection

Short throwing distance

10 Bad angle design 10 Primary

inspectionSecondary inspection 5 500 Select better

angle Waleed 03/23/08 10 5 5 250

Rubber band height on the throwing arm

Low elasticity


10 Bad hole selection 10 Primary

inspectionSecondary inspection 5 500

Use higherpin hole on the throwing arm

Waleed 03/23/08 5 5 5 125

Rubber band height on the bracing arm

Low elasticity


10Short & untighten pin

10 Primary inspection

Secondary inspection 5 500 use linger pin Faisal 03/23/08 10 5 1 50

Ball selection Ball weight and shape

Short throwing distance & inconsistency

10 Bad ball selection 10 Primary

inspectionSecondary inspection 5 500 Better ball

selection Waleed 03/23/08 10 5 1 50

Holding cup assembly Lose pin Released cup 10 Bad assembly 5 Primary


Use better qualitypin

Faisal 03/23/08 5 1 1 5

Assembling holding arm on the base Arm fracture Launching

failure 10 Bad material 1 Primary


Use better quality bracing arm

Faisal 03/23/08 5 1 1 5

15

D M A I CD M AKey Input & Output Variables

16

D M A I CD M A IDesign of Experiment

17


18


20


21

D M A I CD M A I C

Probability Plot Process CapabilityNormal

Normality Test

P-value > 0.05

Normal Distribution

22

D M A I CD M A I CI – MR Chart

23

D M A I CD M A I CXbar – R Chart

25

D M A I CD M A I C

Meet the specifications

DMAIC process

7 new green belts?!?

Conclusions

26

D M A I CD M A I CSix Sigma Project: Katapult

DOE

Six sigma green belt - catapult project

Education

Transcript of Six sigma green belt - catapult project