AMITY SCHOOL OF ENGINEERING AND TECHNOLOGY

B.Tech.(MAE) + MBA

(BATCH 2013-18)

ASSIGNMENT – 3 ( FOR EARLY JOINING STUDENTS )

COURSE – LEAN SIGMA

COURSE CODE - POM 731

Submission Date: 09/03/2018 Max.

Marks: 10

1. Identify a process in an organization and describe its

Process Map.
(2.5 marks)

2. Explain any one technique which can be used in Analyze

Phase of DMAIC. (2.5
marks)

3. Discuss use of DOE in an organization. Illustrate your

answer giving a suitable example.
(05 marks)
Answer 2 ) Cause and Effect Diagram

Purpose

•Identify potential causes of problems

•Summarize process knowledge
•Identify sources of variation
•Facilitate brainstorming

•Benefits

•Increase awareness of factors involved

•Encourage staff participation
•Focus on root causes
•Determine preventive / corrective actions

CAUSES

PEOPLE MACHINES ENVIRONMENT

Pressure Heat
Dust
Training Drop size Humidity
Lighting
Shift change over Temperature
Clean
EFFECT
Time
Poor
bond
Cleaning method
Batch variation
Orientation Temperature Viscosity Gauge
Age of Adhesive
Cause and Effect Diagram

• Ishikawa suggests the following additional steps:

• Step 1: When the relationship between a cause and the effect can be shown

quantitatively, draw a box around the cause.

• Step 2: When the relationship between a cause and the effect is known to
exist, but is

difficult to quantify, underline the cause.

• Step 3: When there is no real proof of the relationship between a cause and

the effect, do not mark the cause in any way.

Answer 3 )

The dispatch date for the Fiesta was rapidly moving toward when Ford discovered that
the presence of brush blemishes on vehicle floor coverings would be unsuitable to clients.
Portage's Body Interior Six Sigma group, drove by Six Sigma Master Black Belt Scott
Sterbenz, started by working with the provider to investigate the procedure used to
fabricate the car cover. They found that the settings of a machine called a needler were
the presumable reason for the reduced item quality.

In any case, the maker stressed that modifying the needler's settings additionally would
influence the extravagance of the cover. The group expected to discover process upgrades
that would take out brush marks while keeping up the extravagance, and they additionally
Cause expected
and Effect Diagram
to think about other basic characteristics, similar to the cover's sturdiness and
stain protection. As they set out to finish the overwhelming errand of enhancing rug
quality in the Fiesta, the quality improvement experts turned to the Design of Experiment
(DOE) tools in Minitab Statistical Software.

In measurements, DOE alludes to the production of a progression of test runs, or tests,

that give understanding into how various factors influence a result, or reaction. In an
outlined trial, agents change in excess of one factor at any given moment, and after that
utilization measurable investigation to figure out what factors are vital and recognize the
ideal levels for these elements. It's an effective and conservative approach to enhance any
procedure.

With time running out, Ford's change group expected to outline an examination that
evaluated the impacts of the six needler settings on the cover's brush markings and
extravagance levels. The examination needed to fulfill a troublesome adjust: it should
have been thorough and dependable, yet in addition expected to limit the cost of materials
and disturbance to the provider's generation plan. Their test was to locate a trial plan that
would accumulate adequate information to advance the needler settings in as few keeps
running as could reasonably be expected.

Because of input from both the producer and the Fiesta improvement group, Sterbenz
utilized Minitab's Response Optimizer apparatus to adjust the ideal settings distinguished
in the underlying DOE. Utilizing the outcomes distinguished in the DOE as a beginning
stage, the Response Optimizer let Sterbenz and his group change the settings to consider
other pragmatic worries from the producer and the improvement group.

After the new cover from the affirmation runs got good appraisals by the underlying
evaluators, tests were sent to Ford's Research and Engineering Center for definite
appraisal. The examples breezed through all tests for strength, recolor protection, and
shading and sheen, and the trial was considered a noteworthy accomplishment by all.
Cause and Effect Diagram
The whole task took 12 days, from the time the issue was characterized to the point
where the arrangement was set up and the procedure was under control. Other than a total
end of brush stamping and a surprising change in the non-abrasiveness of the cover in the
Fiesta, the experimenters accomplished a superior comprehension of the whole
assembling process.

Minitab helped Ford find and actualize an answer for locate the ideal needler settings to
wipe out brush marks and at the same time keep up the extravagance of the cover. The
2011 Ford Fiesta delighted in a very effective dispatch only a couple of months after the
fact, and denoted another turning point in Ford's responsibility regarding greatness and
quality change.