Six Sigma Project - Improve Phase

Six Sigma Project - Improve Phase
Assembly and test capacity expansion.

Improve Phase

The purpose of the improve phase is to carry out improvements and work towards moving from the current state value stream to the desired future state value stream. This blog entry will show how the team carried out the improvements.

"Just do it" items

The "just do it items" identified in the measure and analyze phases have been actioned and purchase orders have been placed for new equipment.

Action plan CSVSM to FSVSM

An action plan was put in place to bring the current state value stream map in line with the future state value stream map, as follows.

• Devise method of de-burring manifolds.
• Purchase new assembly fixtures.
• Create new clean room layout to accommodate dual assembly.
• Introduce preventative maintenance schedule for flow rig filtration change.
• Design and purchase new flow rig.
• Create new test bay layout to house new flow rig, use Test Bay C.
• Automation of Flow Rig.
• Modify assembly and test work order routings in line with FSVSM.

De-burring of manifolds

We were having problems during the assembly procedure with burrs on the small diameter internal bores on the manifolds. We procured a simple de-burring tool which fits in a standard hand drill. (See Fig: 15)

Fig 15: New manifold de-burring attachment, Click image to enlarge.

Purchase new assembly fixtures
Two new assembly fixtures were purchased and are now in place.

Improvements in layout for assembly clean room

The current layout in the assembly clean room is cramped and allows only enough space for one operator to assemble one product at a time. The new layout drawing below Fig: 16 shows the new layout which makes better use of the space by incorporating a new corner bench, This allows adequate space for two products to be assembled simultaneously.

Fig 16: New assembly clean room layout drawing, Click image to enlarge.

Improvements in layout of Test Bay C

The team made a decision to leave the present calibration flow test rig at Test Bay A and to install the new Automated Flow Rig at Test bay C. Test bay C is not being used due to a serious drop in demand for the product line it supported. The below drawing Fig 17 shows how the new flow rig is being incorporated. We will use Test Bay C for most testing and support it with the old manual unit at test Bay A, (e.g. For rework, Surge in demand, Etc.)

Fig 17: New Layout drawing for Test Bay C test cell showing the location of the new flow rig.
Click image to enlarge.

Automation of flow rig

A new software application was developed by the R+D group using the LABVIEW programming environment. This will fully automate the calibration process for Product A. The new system will mean that we will no longer have to rely on the specialized skills of a few operators and we will have an automated system that anyone can use with a small amount of training. (See GUI below Fig 18)

Fig 18: New automated flow rig graphical user interface, Click image to enlarge

Future State Spaghetti Diagram
A new future state spaghetti diagram, (Fig:19), was generated using the new work breakdown structure and future state value steam map created during the analyze phase. It can be clearly seen that the waste of movement has been reduced significantly, by comparing the new spaghetti diagram to the original current state spaghetti diagram.

Fig19: Future State spaghetti diagram, Click image to enlarge.

Next Steps

The team have now completed the first four phases of the DMAIC process. (Define, Measure, Analyze, Improve and Control), The team will now move forward to the control phase.