Six Sigma
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Harley Megaphone Project Green Belt Project
Project Lead: Julio Ramirez Sponsor (Champion): Jose J. Ruiz Company: Casler de Mexico S.A. de C.V. Department: Harley Motorcycle Department Project Timeframe: June 14, 2004 thru March 30 2005
Team Members •Jose Ruiz •Julio Ramirez •Salathiel Duarte •Fernando Caro •Ramon Guerrero •Lorenzo Castro
General Manager QC Department TJ Engineering TJ First Article TJ Engineering Supervisor
IPO Diagram Components: • Steel tubing, laminated plate and fiberglass INPUTS
7 People Cutting, Forming, Welding, Pre-Polish, Chrome, Grinding
PROCESS
OUTPUTS
Process Name
Megaphone Process
Finish Product Efficiency Customer Satisfaction
Tube, Metal Sheet, Fiberglass.
FPY Fill Rate
Problems to focus • Problem Statement – Too much Lead Time to process the product • Project Goal – Reduce Lead Time on Chrome Process by 50% – Primary metric:
Lead Time
– Secondary metrics:
FPY WIP
QFD Diagram
VSM Old Process OLD VALUE STREAMMAP ON MEGAPHONE AREA Forecast
BPCS
Supplies
MRP
Production
Traffic
Customer
Broker
Schedule
WAREHOUSE
Carton
Traffic Dpmt.
Finish Good's
Polish Raw
Fiber & Tube
Tube Plate
I 400
Megaphone CT
I
16.93 min 400
I
Anchor
122.44 min 400 CT
I
Assembly CT 21.16 min
65
Core
I
CT 18.27 min 300
CO 16.2 min
CO 170 min
CO 115 min
CO
LOT 325 meg
LOT 325 meg
LOT 65 meg
LOT 300 meg
71 min
Polish CT
31 min
CO
N/A
I 250
LOT 50 meg
Chrome CT
8 days
CO
28 min
I
QC Inspection
I
250
CT
1 min
112
CO
N/A
LOT 250 meg
Package
LOT 250 meg
CT
10 min
CO
N/A
LOT 50 meg
Broker
Traffic Dpmt.
22.44 min
16.93 min
6 days
12 days
21.16 min
6 days
1 min
31 min
18.27 min
1 day
Traffic Dpmt.
Broker
4.6 days
10 days
10 min
120.80 min
37.4 day 3.8
VSM New Process
FUTURE VALUE STREAM MAP Megaphone Line Study Forecast
BPCS
Supplies
MRP
Production
Traffic
Customer
Schudle
Broker
WAREHOUSE
Traffic
Cartoon
F Goods Fiber & Tube
Tube
Polish Raw
Metal Sheet
I 300
Megaphone
I
Assembly
16.93 min 75
CT
22.44 min 175
CT 21.16 min
CO
16.2 min
CO
170 min
CO
115 min
LOT
50 meg
LOT
50 meg
LOT
50 meg
1.5 days
50
21.16 min
22.44 min
16.93 min
6 days
I
Anchor
I
CT
3.4 days
Core
I CT
31 min
CO
71 min
CO
LOT
50 meg
LOT
I
Chrome
1 day
I 50
QC Inspection CT
0.5 min
N/A
CO
50 meg
LOT
CT
3 days
N/A
CO
50 meg
LOT
50
31 min
12.27 min
1 day
Polish
CT 12.27 min 50
I 25
6.24 min
N/A
CO
N/A
50 meg
LOT
50 meg
6.24 min
.5 min 4 days
Package CT
1 day
110.54 min 17.9 days
Warranty Return Chart
Returns $9,489.87
LA Chrome Histogram
Local Chrome Histogram
Control Phase
House Keeping
BEFORE
AFTER
The 5 “S” objective is: Cleaning the work place, making a good place of work, & eliminate dirt originates.
Kanban Application
Produce only what is required for next Workstation.
SAVINGS ESTIMATES
Summary
Project Lead: Julio Ramirez Sponsor (Champion): Jose J. Ruiz Company: Casler de Mexico S.A. de C.V. Department: Harley Motorcycle Department Project Timeframe: June 14, 2004 thru March 30 2005
Team Members •Jose Ruiz •Julio Ramirez •Salathiel Duarte •Fernando Caro •Ramon Guerrero •Lorenzo Castro
General Manager QC Department TJ Engineering TJ First Article TJ Engineering Supervisor
IPO Diagram Components: • Steel tubing, laminated plate and fiberglass INPUTS
7 People Cutting, Forming, Welding, Pre-Polish, Chrome, Grinding
PROCESS
OUTPUTS
Process Name
Megaphone Process
Finish Product Efficiency Customer Satisfaction
Tube, Metal Sheet, Fiberglass.
FPY Fill Rate
Problems to focus • Problem Statement – Too much Lead Time to process the product • Project Goal – Reduce Lead Time on Chrome Process by 50% – Primary metric:
Lead Time
– Secondary metrics:
FPY WIP
QFD Diagram
VSM Old Process OLD VALUE STREAMMAP ON MEGAPHONE AREA Forecast
BPCS
Supplies
MRP
Production
Traffic
Customer
Broker
Schedule
WAREHOUSE
Carton
Traffic Dpmt.
Finish Good's
Polish Raw
Fiber & Tube
Tube Plate
I 400
Megaphone CT
I
16.93 min 400
I
Anchor
122.44 min 400 CT
I
Assembly CT 21.16 min
65
Core
I
CT 18.27 min 300
CO 16.2 min
CO 170 min
CO 115 min
CO
LOT 325 meg
LOT 325 meg
LOT 65 meg
LOT 300 meg
71 min
Polish CT
31 min
CO
N/A
I 250
LOT 50 meg
Chrome CT
8 days
CO
28 min
I
QC Inspection
I
250
CT
1 min
112
CO
N/A
LOT 250 meg
Package
LOT 250 meg
CT
10 min
CO
N/A
LOT 50 meg
Broker
Traffic Dpmt.
22.44 min
16.93 min
6 days
12 days
21.16 min
6 days
1 min
31 min
18.27 min
1 day
Traffic Dpmt.
Broker
4.6 days
10 days
10 min
120.80 min
37.4 day 3.8
VSM New Process
FUTURE VALUE STREAM MAP Megaphone Line Study Forecast
BPCS
Supplies
MRP
Production
Traffic
Customer
Schudle
Broker
WAREHOUSE
Traffic
Cartoon
F Goods Fiber & Tube
Tube
Polish Raw
Metal Sheet
I 300
Megaphone
I
Assembly
16.93 min 75
CT
22.44 min 175
CT 21.16 min
CO
16.2 min
CO
170 min
CO
115 min
LOT
50 meg
LOT
50 meg
LOT
50 meg
1.5 days
50
21.16 min
22.44 min
16.93 min
6 days
I
Anchor
I
CT
3.4 days
Core
I CT
31 min
CO
71 min
CO
LOT
50 meg
LOT
I
Chrome
1 day
I 50
QC Inspection CT
0.5 min
N/A
CO
50 meg
LOT
CT
3 days
N/A
CO
50 meg
LOT
50
31 min
12.27 min
1 day
Polish
CT 12.27 min 50
I 25
6.24 min
N/A
CO
N/A
50 meg
LOT
50 meg
6.24 min
.5 min 4 days
Package CT
1 day
110.54 min 17.9 days
Warranty Return Chart
Returns $9,489.87
LA Chrome Histogram
Local Chrome Histogram
Control Phase
House Keeping
BEFORE
AFTER
The 5 “S” objective is: Cleaning the work place, making a good place of work, & eliminate dirt originates.
Kanban Application
Produce only what is required for next Workstation.
SAVINGS ESTIMATES
Summary
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