Practice probem 2 Answer (1)
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509LEC
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Industrial Engineering
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Dec 6, 2023
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1. Match the Six Sigma players to their corresponding roles (justify your choices):
Roles and Responsibilities
Six Sigma Players
Works full-time on SS projects
Black Belt
Expert in statistics. Helps teams and resolves
conflicts
Master Black Belt
Responsible for implementing solutions
Process Owner
Responsible for ensuring project completion
and delivery of results
Project Champion
Works part-time on SS projects.
Green Belt
2. (20 pts) Think about three specific examples of the seven wastes of Lean that could be addressed with
a Six Sigma project. This could be at your workplace or a generic process you are familiar with. Then, try
to operationalize the "what is wrong."
Identify the process and where it occurs. What would be the
primary metric associated with this project?
Be concise. Use the table below as a reference.
Waste
Example
Describe what is
wrong
Process
Primary Metric
Transportation
Waste
The train has inefficient
headways and routing
Increased
power
consumption,
Bad review from
customer,
increased cost
Evaluating
transportation
planning and
route selection
using historical
data to optimize
future routes
Input
Inventory
Waste
Often request 25%
inventory based on
conventional policy. For
the new project it keeps
the same %.
Increased cost,
can not update
with new parts,
unorganized
stock room,
Helps Create an
inventory control
process and
configuration
management
process
Output
Motion Waste
Maintenance team takes
longer time to get the
tools, spare parts, and
information in their hand.
Long time to
troubleshot,
compromised
quality of repair,
provide
information on
how process
structure and
work
environment
optimization
might minimize
motion waste.
Input
3. (10 pts) What is a SIPOC diagram (map)? How is it used in the Define phase?
SIPOC Diagram is a high-level process map and a tool that summarizes the Input and output of one or
more processes in table or diagram form commonly used in the defined phase of the six sigma DMAIC.
It’s an acronym that stands for S= Supplier I= Input P=Process O=output C=Customer. The SIPOC diagram
helps the company in determining how a process operates. It identifies the project's owner and server
and makes an estimation of how well an input is utilized in the process. It also determines if the output is
satisfactory and eliminate or create or change a process accordingly. This tool came out in 1980’s in use
as part of the total quality movement. And today it is vastly used in six sigma, lean manufacturing, and
BPM (Business Process Management)
Using SIPOC in the Define step resembles the following:
For example, In New York City Transit a systemwide cable replacement project is 2 years behind. We
need to identify the process that we want to improve at the beginning of the project. Then identify the
suppliers, Inputs outputs and the end users or the customers.
In the very first steps we list down all the
elements SIPOC diagram. For an Example:
Supplier
Input
Process
Output
Customer
1. Cable company-EIS
Wire and Cable
2.Tray Manufacturer-
Selco
3. Installer and
Contractor- Comstock
1.
Scope of
Work
2.
Contractor
Proposal
3.
Proposed
Schedule
4.
Budget
5.
Survey
and
Drawings
6.
Cable
Spec
7.
Tray Spec
1.
Review
Contractor
Proposal
2.
Review
Drawings
3.
Inspect
Cables and
Trays
4.
Inhouse
Coordinator
5.
Witness
testing
6.
Sign the
deployment
.
7.
Accept
Deliverables
1.
Cables
2.
Trays
3.
Installation
of New
Cable
4.
Installation
of Cable
Tray
1. New York City
Transit
2. Department of
Transportation
4. Develop a SIPOC of ordering groceries online and having them delivered to your customer's home.
Supplier
Input
Process
Output
Customer
1.
Wholesal
e supplier
2.
Grocery
with
online
platform
3.
Delivery
service
provider
1.
inventory
2. Stock
Availability
3.Customer
customer
grocery
order
4. payment
information
5.delivery
address
6. Delivery
time
1.
Customer selects
item.
2.
Order goes to the
cart.
3.
Customer reviews and
confirms.
4.
Online platforms
process the order and
send this to grocery
and delivery service.
5.
Grocery packs that
order.
6.
Delivery service sends
his driver.
7.
Driver delivery the
order to the customer
1.
Order
confirmation
2.
Receipt
3.
Delivered
groceries.
4.
Confirm
delivery.
5.
Tips
1. Customer
placed the
order
5. Megasigma Corp. has a process they believe is operating near the Six Sigma level and wants to verify
this. If the specification for a critical part in the process is 2.75 cm +/- 0.05, and the standard deviation is
0.02, at what sigma level is the process operating?
USL= 2.75+.05= 2.80
LSL= 2.75-.05= 2.70
Standard Deviation σ= 0.02
Σ Sigma Level = (USL-LSL)/2σ= (2.80-2.70)/ (2*.02) =2.5
The process is operating at 2.5 sigma level.
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6) Puragua Corporation makes water meters sold to contractors and municipal water departments.
Analyze their quality costs, group them into the four standard cost categories (prevention, appraisal,
internal failures, and external failures), and prepare a Pareto chart showing the company's quality costs
incurred over the past year. How might this information be used to help define an SS project?
Particulars of Cost
Cost
Incurred
Total Cost Incurred
Percentage
Preventive Costs
Quality Audits
10,000
10,000
1.38
Quality Training
27,500
37,500
3.79
Customer User Surveys
17,000
54,500
2.34
Supplier Rating
15,000
69,500
2.07
Appraisal Costs
Measurement Equipment
46,800
116,300
6.46
Laboratory
20,000
136,300
2.76
Support
Internal Failure Cost
Scrap Cost
200,000
336,300
27.59
Reinspection Retest
40000
376,300
5.52
Purchase Material Reject
34000
410,300
4.69
Design Corrective Action
12000
422,300
1.66
Rework Costs
150000
572,300
20.69
External Failure Cost
Customer Returns
63,700
636,000
8.79
Customer Penalties
55,000
691,000
7.59
Warranty Claims
34,000
725,000
4.69
Total Cost of Quality
725,000
100
According to the Pareto analysis, about 80% of the effects result from 20% of the causes; as a result, it
may be used to identify the areas that require special focus if significant progress is to be made. Pareto
analysis demonstrates that six sigma may be simplified to first eliminate losses.
Pietro analysis in a table:
particular of cost
Scrap
200000
27.59
Rework
150000
20.69
Customer Returned
63700
8.79
Customer Penalties
55000
7.59
Reinspection
40000
5.5
Measurement Equipment
46800
6.46
Warranty Claims
34000
4.69
Purchased Materials
Reject
34000
4.69
Total
86
In order to really profit from Pareto Analysis, as can be seen from the above, the entity must seek to
reduce the costs associated with scrap and rework.
7. (30 pts.) You were given the following dataset related to the failures found on each day of the
week for the last six weeks. What would you do to start understanding the current state?
What questions would you like to answer? Identify the graph that will answer, and then provide
some insights gained from the exploratory results. You are expected you use two different
tools.
Ans:
What is the overall trend in failures over the six weeks?
Which day of the week had the highest and lowest failures on average?
How does the distribution of failures vary from week to week?
Are there any noticeable patterns or anomalies in the data?
Is there a correlation between failures on different days of the week?
Calculate basic descriptive statistics for each day of the week for the six weeks. You can calculate
the mean, median, standard deviation, minimum, and maximum values for each day.
Create a summary table to display these statistics.
Day
WK1
WK2
WK3
WK4
WK5
WK6
Sun
4
3
5
10
7
7
36
Mon
9
7
6
9
7
4
42
Tues
7
12
6
4
12
9
50
Weds
10
5
7
10
12
6
50
Thurs
7
7
6
8
13
7
48
Fri
13
11
6
8
13
10
61
Sat
11
17
11
6
10
6
61
61
62
47
55
74
49
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