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Workorder Error Reduction Six Sigma Case Study

Steven Bonacorsi, Lean Six Sigma Master Black Belt, led the ACFC "At the Customer, For the Customer" Six Sigma Initiative at General Electric. Each Case Study follows the Quad Chart or 4-block approach. Steven Bonacorsi is the author of the Six Sigma and newer Lean Six Sigma Tollgate Templates that hundreds of thousands of practitioners have leveraged for documenting their project best practices and results. Steve Bonacorsi is the President of the International Standard for Lean Six Sigma (ISLSS) and Founder of the LinkedIn Lean Six Sigma Group http://www.linkedin.com/groups/Lean-Six-Sigma-37987, author for the Process Excellence Network, Executive Management Consultant for e-Zsigma, and Honorary Advisor for the International Six Sigma Council (ISSC).

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150 views2 pages

Workorder Error Reduction Six Sigma Case Study

Steven Bonacorsi, Lean Six Sigma Master Black Belt, led the ACFC "At the Customer, For the Customer" Six Sigma Initiative at General Electric. Each Case Study follows the Quad Chart or 4-block approach. Steven Bonacorsi is the author of the Six Sigma and newer Lean Six Sigma Tollgate Templates that hundreds of thousands of practitioners have leveraged for documenting their project best practices and results. Steve Bonacorsi is the President of the International Standard for Lean Six Sigma (ISLSS) and Founder of the LinkedIn Lean Six Sigma Group http://www.linkedin.com/groups/Lean-Six-Sigma-37987, author for the Process Excellence Network, Executive Management Consultant for e-Zsigma, and Honorary Advisor for the International Six Sigma Council (ISSC).

Uploaded by

Steven Bonacorsi
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Six Sigma DMAIC Project

GE Aircraft Engines Account

Project Leader/Green Belt: Dave Smith Project Leader Title: Solution Design Consultant Project Start Date: May 21, 2003

Master Black Belt: Steven Bonacorsi

Six Sigma in Action Work Order Error Correction


Customer Profile 17,000 Seat, Global design & production company for Aircraft Engines Business Problem & Impact Process Capability Before
Fixed assets work order scanning (barcode) inherently introduces errors. Multiple individuals use the existing process, which causes 40 - 50% error rate. The existing process is not cost effective, since errors are corrected manually.
65 (9%) Defects 628 (91%) Successful

Measure & Analyze


Data Collection:
Historical data was collected over a 1 month period to quantify the extent of errors.

Root Causes:
Serial Numbers for IBM T30 laptops and DELL monitors fail import every time and barcode being different between the shipping box and equipment were determined to be root causes.

Z_ST = 1.3

Process Capability After

Improve & Control


Real Time scanning was implemented to in December 2003. Scanner accuracy will be monitored daily and control charts will be used Qrtly to validate process improvements.

Results/Benefits
At the end of the project, real time scanning reduced rework 100% and cycle time per hardware component reduced from 10 to 5 seconds resulting in annual efficiency savings of >9.7 K!

Units Defects DPMO Z (ST) Z (LT)

Baseline 693 85 93,795 2.82 1.32

Improved 240 0 0 6.0 4.5

A savings of US $9,716 in 2003!

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