Training Institute Provides Six Sigma Success to Local Companies
By Ron Tozydlo
Each year the ASQ Chicago Section Institute for Quality Control Training’s Six Sigma II: Laboratory class divides into teams to perform Six Sigma projects at local companies using the methodology and tools learned in Six Sigma I: Theory. As in past years, teams formed in the 2002-2003 winter term helped companies realize profitable gains.
Two teams were established in the first week of class in December 2002; one team would work at Courtesy Corporation in Wheeling, Illinois, a plastic injection molding company, and the second team at Elkay Manufacturing Company, a stainless steel sink manufacturer in Broadview, Illinois. Teams were formed based on student preferences and individual expertise. After the initial team-forming class at Harper College, each team met at its respective company for the rest of the term until project completion. Both teams utilized Six Sigma’s Define-Measure-Analyze-Improve-Control (DMAIC) methodology.
The Courtesy team utilized many tools during the DMAIC implementation in investigating the scrap rate of a particular molded product. These included Pareto Charts, t-test statistical analyses, multi-vari charts, probability plots, and run charts, to name some. Conclusions drawn from these analyses indicated that the tool repair request procedure should be enhanced to list more descriptive information, to attach examples of defects, and to measure the effectiveness of the repair; the accuracy of recorded information of defects must be improved; analyze trends of daily scrap rates; and tool alignment should be checked periodically. A design of experiment (DOE) for the analysis of cycle checklists was also recommended. The project recommendations that were implemented reduced the scrap-rate by 20% with an estimated annual savings of $60,000.
Elkay’s project investigated the defect rate of a welding operation using the
DMAIC approach. First the types of defects were measured and charted on a Pareto
Chart. This indicated that the defect occurring most frequently was a
“burn-through” which literally occurs when the weld burns through the stainless
steel and creates a hole. The project then focused on lowering the incidence of
burn-through. Many of the same tools that the Courtesy team used were utilized
at Elkay as well as measurement system analysis (gage R&R), failure mode and
effect analysis
(FMEA), and the planning of a five factor – two level DOE to be run in two
blocks. Recommendations to the process included amongst others: follow work
instructions carefully; utilize data gathered on forms to enhance the process;
change tungsten electrodes after a fixed number of operations and perform a
reliability study on electrode wear; and perform preventive maintenance on the
shear blade which is used to cut the steel before welding. The Elkay project has
realized an estimated annual savings of $20,000 by reducing scrap rate from the
welding process by 70%.
As indicated above, the Training Institute’s Six Sigma projects have helped companies, but students benefit greatly also. The Six Sigma projects are great hands-on learning tools for students. Students are able to observe the actual process, perform measurements and analyses from data generated, interview key personnel involved in the process, all while learning Six Sigma implementation. The Courtesy and Elkay projects, as well as other projects implemented in previous Six Sigma II: Laboratory classes, involved a student that was also an employee of that company. So, if you would like your company to benefit from Six Sigma, you or one of your employees should enroll in Six Sigma I: Theory that begins this fall (see pages 6 and 7 for TI information). Perhaps you will request that a project be performed at your company for Six Sigma II. After all, who would pass up the opportunity of obtaining free consultancy from quality professionals?