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Design For Six Sigma Green Belt Project:
Design For Six Sigma Green Belt Project:
HONEYWELL (KCNSC - DOE)
HONEYWELL (KCNSC - DOE)
Completion of Design for Six Sigma Green Belt requirements of knowledge courses, identifying root causes of an existing manufacturing problem and developing/testing solutions before implementation. Product is classified to the Department of Energy, technical details of the product cannot be shared.
What:
After identifying production's highest defect product as a mechanical stack up dimension caused by human error assembly.
Problem: 38% of total Defect NCRs during are cause by the critical keyway stack-up dimension, length and/or width, to be out of tolerance which results in wasted time and risk of missing due dates
Goal: Eliminate NCRs cause by out of tolerance measurements for both length and width
How:
Thought Map
Process Map
FMEA / PFMEA
Modified Pugh
Control Plan
Mistake Proofing
Process Map indicated potential early defect detection, which resulted in allowance for rework. Tools indicated no instructions for proper orientation for the install. A work instruction was created to aid and bring awareness of the repeated defect to production.
Results:
Designed installation fixture to mistake proof the installation
Worked with design agency to shift lower limit tolerance for Mistake Proof Install
Estimated Projected Cost Savings: $550K/Year based on program life/defects per unit (DPU)
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