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OVERVIEW
Six Sigma
Motorola Experience
GE Experience
GE Experience
GE plastics
GE Medical Systems
Integral MQS
Achievements
Sample of Six Sigma Projects
Implemented
11
Project 1:
Optimization of Calcium
Addition
12
Project 1:
Optimization of Calcium Addition
Opportunity Statement: (Problem Definition)
EFS loss of 1,481,544 L.E per year due to the uses of the heated
Calcium-wire after Calcium optimization.
The process current sigma level is 2.15
Goal Statement:
Project 2:
Reduce Casting Time
14
Project 2:
Reduce Casting Time
Opportunity Statement: (Problem
Definition)
Goal Statement
16
Opportunity Statement:
Currently, in EFS, there are 0.62% defective
Coils due to width drop after the hot strip
Mill process. This represents a revenue loss
of 6,704,422.50 L.E. per year. The process
current sigma level is 3.76
Project Goal :
Project Scope:
Reduce
Team Selection:
Activity
Define Phase
Measure Phase
Analyze Phase
Improve Phase
Control Phase
From
15/01/2006
15/02/2006
01/05/2006
15/05/2006
01/07/2006
To
15/02/2006
30/04/2006
15/05/2006
30/06/2006
10/07/2006
Dr.Gamal Megahed
Nabil Douban
Ahmed Nabil
Usama Ahmed
Mohammed Awad
Mohammed Ibrahim
Ahmed Attala
Niraj Singh
Sponsor
Black Belt
Adhoc
Member
Member
Member
Member
Member
TD Manager
Financial Manager
HSM Process Engineer
HSM Production Eng.
Quality Control Eng.
Automation Engineer
SKP in Charge
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Return Goods:
Returns Invoices:
of its contents.
Partial R. Invoices:
Contract :
The invoices which are partially returned, the customer accepted some
of its contents and returned the others.
Local or exportation tenders.
2- Project Selection
Work Break Down Structure
Sales
Net Sales
Other
Customer
Distributors
Returns
Pharmacies
Distributors
Pharmacies
Invoice Returns
Other
customers
Return Goods
Scrape
Rework
Due to Expiration
Others
At Pharmacy
At Company
Returned Products
Returned products
Contract R. partially
Contract R. Invoice
Contract Returns
Invoice R. partially
Invoice Returns
Returned Goods
6.0%
2.0%
92.0%
Sales
Samples
Returns
6%
100%
80%
60%
40%
20%
0%
2%
18%
41%
7%
11%
21%
0.00%
Invoice R.
Return
Goods
Facts
Pareto Chart of Customer Type ( Returned Goods Units 2004 - 2006)
100
2000000
80
60
1000000
40
500000
0
Customer Type
Count
Percent
Cum %
20
Pharmacies
1221801
56.8
56.8
Distributers
910889
42.4
99.2
Other
16881
0.8
100.0
Percent
Count
1500000
Business Case
Opportunity Statement
Facts
Project Scope
Project Objectives
Project Charter
Business Case
The defect of returned products
Based on expiry date cause loss of about
3,000,000 LE per year.
Opportunity Statement
Currently ,the returned products
due to expiry date represent 18% defect from all
returned Products The Company Scrape about 82%
from them. This represent loss of about
3 M L.E. per year. The current sigma level 0.6
Project Goal
1- Reduce the cost of returned products by
1,000,000 L.E. per year.
2- Improve process sigma level from
0.6 to 1.6 Sigma.
3- Improve the return cycle.
4- Increase the customer satisfaction.
Project Scope
The Sales From Getting the Customer Order until The
Expired product Execution.
Time Schedule
Define 2 Weeks
Measure 2 Weeks
Analyze 2 Weeks
Improve 1 Month
Control 1 Month
Thank You
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