Six Sigma Overview

The 12 Steps

DEFINE The Practical Problem

Step 0: Project Selection

MEASURE
Step 1. Select CTQ Characteristics Step 2. Define Performance Standards Step 3. Measurement Systems Analysis

The Statistical Problem

ANALYZE
Step 4. Establish Process Capability Step 5. Define Performance Objectives Step 6. Identify Variation Sources

The Statistical Solution

IMPROVE
Step 7. Screen Potential Causes Step 8. Discover Variable Relationships Step 9. Establishing Operating Tolerances

CONTROL The Practical Solution

Step 10 Define and Validate the Measurement System on Xs Step 11. Determine Process Capability Step 12. Implement Process Control

Six Sigma Overview

Step 0: Project Selection

Step 0: Defining our project...

g
GE Electromaterials
Decision Maker Information/ Criteria Dashboard/FGI Survey Results Business Quality Initiatives

10 Step Project Review Process

Outcomes

Selection Phase 6 sigma owner 1) Define Customer Needs 2) Prioritize Initiatives 3) Define Functional Area of Focus 4) Key Process Identification 5) Define Cost of Failure/ Financial Impact 6) Define Simple Problem Statement 7) Identify Macro CTQs 8) Macro CTQ Flowdown 9) Business Approval of Project 10) Kick-off

Business Level CTQs

Business Level CTQ Flowdown

Plastics Measurements Guidelines

Impact of process on Business level CTQs Process Level CTQs Process Level CTQ Flowdown Correlation of project impact to Business Level CTQs Business Approval of Project

Cost of Failure

EMDs 10-step process

g
GE Electromaterials Communications
Documentation vs Goal

Aug 1997

Altron Dashboard

98.5%
60 75 90

39%
60 25 75

100%

100% 98.50%
25

OTS vs Goal
100%
90

Documentation %

98% 96%

ow

ow

80%

94% 92% 90% 88% June July Aug 92.00%

OTS %

Goal

100

60% 40% 29% 20% 0% June July Aug Sep 33.00% 39.00% OTS Goal

Document Goal

Goal

100

Tech Service

GE Electromaterials

Six Sigma

On-Time Shipment

Documentation
Sep

Project Contract
1. The Project titled _______________________________ has been approved as a ( BB / GB ) Project. The Black Belt assigned to this project is __________________________. The Green Belt (if applicable) is ________________________.
60 75 90

Responsiveness

Packaging vs Goal
100% 100% 100.00%
25 60 75 90

100%

100% 98%

100%

100.00%

Packaging %

Produc Quality vs Goal

98% 96% 94% 92% 90% 88% June July Aug Sep 92.00% Packaging Goal
0

Now

Goal

100

Prod Qual %

93%
25

96% 94% 93.00% 92% 90% Prod Qual Goal

Packaging

The MBB is _____________________. 2. The initial Project completion date is set at ________________________. 3. The Black Belt is required to updated QPID to the initial level and coordinate with the MBB to update all further steps. 4. This project will be updated bi-weekly at the Six Sigma Project Review. The Black Belt is responsible for coordinating team efforts and educating the team on the process steps, as the projects evolves. 5. If any blockers are identified in the process, the following steps should be taken, in order:
0

Now

Goal

100

88% June July Aug Sep

Product Quality

Issue Resolution
Corrective Actions (CAR)
Process
1. On-Time Delivery 2. Labels

Customer Service

Owner
Noonan Ferguson

Status
In Process In Process

Response Time Confirmation by 3:00pm

On-Time Shipment

Trend

Documentation
Correct Matl Certs (CSC) Labels

Trend

Packaging
Vacuum Quantity Key Fail Pass

Trend 0 59 0 59

Product Quality
Meet Spec Prepeg Test Dates Color Consistency
Thickness Copper Stamping Diametric

Trend

a. Notify Black Belt: BB addresses situation with blocker. b. Notify MBB: MBB addresses situation with the blocker. c. Notify Staff at Six Sigma Project Review. 6. Other:

On-time( +5,0) GETEK Pre-preg GETEK M/L

36 59 19 24 17 35

1 59 0 59 0 59

0 59 0 59 0 59 4 59

Green Belt

Black Belt

MBB

Champion

GM

Team Selection & Timing

Project Contract

Customer Dashboards

Six Sigma Overview

Step 1. Select CTQ Characteristics

Step 1: Deciding where we start ...

F.M.E.A.Form

GE Plastics

Example - Ice Maker

x x
Importance
Scheduling Order entry Fab Interpetation

xx xx
Packaging Ship

xx
Speciality

x
Updating Cps /Sales Rep Warehouse/ Cut Center

Process Step/Part Number

Potential Failure Mode

Potential Failure Effects No ice

S E V 10

Potential Causes Water valve adjustment set incorrectly Freezer setting too high

O C C 8

Current Controls Visual inspect

D R E P T N

Actions Recommended

Dispenser Cam & gear must function iced up 50,000 cycles before failure

7 560 Elim. need for adjustment

10

Visual inspect

3 60

CTQs
Paperwork Size Issues Product Issues Qty Stamp Packaging Totals

Design heater for more even distribution

5 3 4 4 3 3

9 3 1 2 2 2 78

1 2 3 1 1 1 33

5 3 1 5 5 4 85

2 1 1 1 1 2 30

3 1 1 9 1 9 88

3 1 1 1 1 6 47

9 6 1 2 3 4 96

9 4 2 5 4 5 112 112

Broken motor

No ice

10

Lead wires not 4 crimped properly Coil burned out 3

4 160 Redesign crimp or proc. check 4 120 Redesign sys.for effic. ice release 1 14 Customer educ.; Change detection method

10

Feeler arm bent

Continuous ice

Customer abuse

FMEA
QFD
Variable ('Y'): Customer Satisfaction with Label

Variable ('Y'): Customer Satisf action with Label

Product Manager: CT Qs

GETEK Sales Team: CTQs

Easy Readability
Font Size Plain English Data Arrangement Label Size Text Direction GE Logo Not Hand Written Color of Label/Text

Accuracy
Paper Matches Contents Quantity Label Matches All Other Paperwork Customer Data Correct Link to Order Inventory Complete Required Fields

Complete
General Info: EMD: -Lot & Skid # -Req # SHIPPING: -Case # /Weight -Package Size PRODUCT: -Grade/Clad/Thick -Plain English/Cert - QTY /Size /Grain Customer Specific: Part Number P/O Number Cust Name Location Cert/Spec Date (Ship) Due Date

Adhesiveness

Easy Readability
Font Size Plain English Arrangement of Data Label Size GE Logo: Relation to Data Not Hand Written

Accuracy
Paper Matches Contents Quantity Label Matches All Other Paperwork Customer Data Correct Link to Order Inventory Complete Required Fields General Info:

Complete
Skid # Req # /Item Date /Case # / Weight Package Size Grade /Clad /Thick Plain English /Cert QTY /Size /Grain Warehouse Locator

Adhesiveness
Packing to Customer Shelf Life of the Sticker >1 yr Replaceability Flatness of Package

Packing to Customer Shelf Life of the Sticker >1 yr Replaceability

Customer Specific:
Part Number P/O Number/Item Customer Name Location Cert/Spec Date (Ship) Due Date Manufacturing

Professional
GE Logo Laser Quality HQ info Colors Size and Spacing Benchmark Competition Marketing Appeal (R.W. Salter)

Bar Codes
Customer/industry standard Items to be Bar Coded - shop movement/shipping - customer info Standard Format - size/unobscured/quality Link to GEMMS Link to Test Data:Futuristic/Cert

U/L Requirements

Link to other Paperwork on Box

Min # of pieces Location of Labels Consistency Compare with competitors

Professional
GE Logo Laser Quality HQ info (address/phone) Black/White Overall Size and Spacing Benchmark Competition

Bar Codes
3 of 9 Standard - customer/industry standard Items to be Bar Coded - shop movement/shipping - customer info Standard Format - size/unobscured/quality Link to Test Data - Futuristic/Cert

U/L Requirements

Link to other Paperwork on Box

Minimize the # of pieces

Registered Trademark -GETEK -GEPEG

Location of Labels Consistency Compare to competitors

Variable ('Y'): Customer Satisfaction with Label Shop Floor/ Transportation: CTQs

Variable ('Y'): Customer Satisfaction with Label Photocircuits Glen Cove: CTQs

Not an interrogation!!

Easy Readability
Font Size Label Size GE Logo: Relation to Data Not Hand Written Spacing for QTY (able to change)

Accuracy
Data Accuracy from Customer Service Should have Packer/FCO fill out Packing Label Bar Code from Shop Order Routing Information Information flow from Line to Label process

Complete
EMD: - Lot # /Skid # /Oper - Req # /Item SHIPPING: - Date /Case # / Weight - Package Size PRODUCT: - Grade /Clad /Thick - Plain English /Cert - QTY /Size /Grain

Easy Readability

Accuracy
Paper Matches Contents Quantity Label Matches All Other Paperwork Customer Data Correct Link to Order Inventory Complete Required Fields General Info:

Complete
Skid # Req # /Item Date /Case # / Weight Package Size Grade /Clad /Thick Plain English /Cert QTY /Size /Grain Warehouse Locator

Adhesiveness

Font Size Plain English Arrangement of Data Label Size Not Hand Written

Customer Specific:
Part Number P/O Number/Item Customer Name Location Cert/Spec

Packing to Customer Shelf Life of the Sticker >1 yr

Professional
GE Logo Laser Quality HQ info (address/phone) Overall Size and Spacing Benchmark Competition

Bar Codes
Customer standard Items to be Bar Coded - shop movement/order - customer info/CPS Standard Format - size/unobscured/quality Link to Test Data - Futuristic/Cert

Link to other Paperwork on Box

Minimize the # of pieces Location of Labels Consistency Compare to competitors

Professional

Bar Codes
3 of 9 Standard Items to be Bar Coded - customer info - not on label Standard Format - size/unobscured/quality Link to Test Data - Futuristic/Cert

Link to other Paperwork on Box

Location of Labels Consistency Compare to competitors

GE Logo Laser Quality Black/White Overall Size and Spacing Benchmark Competition

CTQ Flowdown

Six Sigma Overview

Step 2. Define Performance Standards

Step 2: What is a defect...

2ND (RE-) RECOMMIT DATE GIVEN IF WE HAVE ANY ISSUES IN FAB PREVENTING HITTING GOAL, SUCH AS; HOT ORDERS, DOWNTIME, LOW PRODUCTION, OT, OR BAD SCHEDULES, THEN A 3RD RE-RE-RECOMMIT DATE MAY BE GIVEN PUT IN SCHEDULE, TREAT, PRESS, FAB NO TREAT, PRESS, FAB YES TREAT, PRESS, FAB YES

10 9 8 7 6 5

DOES THIS ORDER TAKE PRIORITY

NO

IS THERE TREATER TIME

GIVE RECOMMIT DATE

YES

NO RECEIVE ORDER IS THERE INV. IN WAREHOUSE CUT AT SERV. CENTER

NO

Process Mapping

Praegitzer

Bar code

US Circuits

QTY

CUSTOMER SERVICE/ORDER ENTRY

MANUFACTURING

LA Warehouse

0
Part # Paperwork Dates not CPS BOM

HISCO

Trend

Pycon

Pareto of Defects

L100 Worksheet - Sigma Scorecard for Attributes

CTQ carbon Black example 2 example 3 example 4 D 2 34 1 22 U 100 59 213 289 OP 1 1 1 1 TOP 100 59 213 289 0 0 0 0 0 Totals 59 n/a n/a 0 661 DPU 0.020 0.576 0.005 0.076 n/a n/a n/a n/a n/a n/a n/a DPO 0.020 0.576 0.005 0.076 n/a n/a n/a n/a n/a n/a 0.089 DPMO 20,000 576,271 4,695 76,125 n/a n/a n/a n/a n/a n/a 89,259 Yield 98.00% 42.37% 99.53% 92.39% n/a n/a n/a n/a n/a Shift 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 Sigma 3.55 0.00 4.10 2.93 n/a n/a n/a n/a n/a n/a 2.85 L.T. Z-value 2.05 -0.19 2.60 1.43 n/a n/a n/a n/a n/a n/a 1.35

ECD

PULL FROM WHSE

CUT THERE

GIVE COMMIT DATE

PRESS, FAB

Peavey

Westak

CUT IN COSHOCTON

GET CLOTH, TREAT, PRESS, FAB

Parlin

Hewlett Packard

YES

YES

YES

Winonics

YES

NO

Litton

PCC

Pam Eng

Confidence Limits (alpha= on DPMO lower upper 2,431 440,672 119 48,320 n/a n/a n/a n/a n/a n/a 68641.3 70,384 703,950 25,879 112,987 n/a n/a n/a n/a n/a n/a 113627

Photocircuits

Circuitwise

Altron

Merix

SEND TO MANU. TO CUT AT COSH

NO

DO WE HAVE MATERIAL

NO

DO WE HAVE TREATED MATL

NO

IS THERE CLOTH?

0.95

on Sigma lower upper 2.97 0.00 3.45 2.71 n/a n/a n/a n/a n/a n/a 2.71 4.32 0.00 5.18 3.16 n/a n/a n/a n/a n/a n/a 2.99

n/a 1.50 91.07% 1.50

L100 / L2 Spreadsheet

Six Sigma Overview

Step 3. Measurement Systems Analysis

Step 3: Is the measurement real...

Gage Repeatability & Reproducibility Analysis:
Standard GRR (Long Form) NOTE: The defaults of the following worksheet are intended for 3 Oper, 3 Trials and 10 Samples (Parts). This worksheet is also flexible to less number of Oper, Trials and Samples Make sure you use the appropriate constants (D4, K1 and K2), if you use less number of trials or samples. Operator A B Sample # Trial 1 Trial 2 Trial 3 Range Trial 1 Trial 2 Trial 3 Range 1 5.70 5.70 5.70 0.00 5.75 5.75 5.75 0.00 2 4.20 4.20 4.20 0.00 4.25 4.25 4.25 0.00 3 0.40 0.40 0.40 0.00 0.50 0.50 0.50 0.00 4 1.70 1.70 1.70 0.00 1.75 1.75 1.75 0.00 5 1.80 1.80 1.80 0.00 1.75 1.75 1.75 0.00 6 1.60 1.60 1.60 0.00 1.50 1.50 1.50 0.00 7 0.70 0.70 0.70 0.00 0.75 0.75 0.75 0.00 8 1.50 1.50 1.50 0.00 1.50 1.50 1.50 0.00 9 0.00 0.00 10 0.00 0.00 C Trial 1 5.75 4.25 0.50 1.75 1.75 1.50 0.75 1.50 Trial 2 5.75 4.25 0.50 1.75 1.75 1.50 0.75 1.50 Trial 3 5.75 4.25 0.50 1.75 1.75 1.50 0.75 1.50 Range 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

GageR & R of 10.12%

Totals Daily Ave. Daily Std. Final Ave.

17.60 2.20 1.81 Xa

Ra Rb Rc Sum R

17.60 2.20 1.81 2.20

0.00 0.00 0.00 0.00 0.00

17.60 2.20 1.81 Ra

0.00 0.00 0.00

# Trials 2 3

17.75 2.22 1.82 Xb

D4 3.27 2.58

17.75 2.22 1.82 2.22

17.75 2.22 1.82 Rb

0.00 0.00 0.00

17.75 2.22 1.82 Xc

17.75 2.22 1.82 2.22

Max X Min X X Diff Mean Stdev

17.75 2.22 1.82 Rc

2.22 2.20 0.02 2.21 1.71

0.00 0.00 0.00

(R) x (D4) = UCLr UCLr = 0.00

Tolerance

UCL 0.25

LCL -0.25

Measurement Analysis
Repeatability - Equipment Variability (E.V.) E.V. = (R) x (K1) E.V. = 0.00 Reproducibility - Appraiser Variation (A.V.) A.V. = ((Xdiff * k2)^2 - ((E.V.)^2/(n x f)))^.5 A.V. = 0.05 Repeatability and Reproducibility (R&R) R & R = ((E.V)^2 + (A.V.)^2))^.5 R&R= 0.05 Trials K1 2 4.56 3 3.05

Fully Acceptable Gage R&R (Xbar/R) for Data System Measurement for the measurement of % Tolerance Analysis downtime.
% E.V. = 100((E.V.)/(Tolerance)) % E.V. = 0.00 3

Gage name: Date of study: Reported by: Tolerance: Misc:

Xbar Chart by Operator

1 2

Operator*Part Interaction
3.0SL=2.815 2.5

Operator
1 2

Sample Mean

Trials 2 K2 3.65 n = number of parts f = number of trials

3 2.70 8 3

% A.V. = 100((A.V.)/(Tolerance)) % A.V. = 10.12 2

X=1.875

Average

2.0

% R & R = 100((R&R)/(Tolerance) % R & R = 10.12 1

-3.0SL=0.9347

1.5

Part

351

352

Sample Range

Identifying if how we measure downtime is accurate!

1

R Chart by Operator

Response BY Operator
2

1.5 1.0 0.5 0.0

3.0SL=1.634

2 R=0.5000 -3.0SL=0.000 1

Oper

Components of Variation
100 90 80 70 60 50 40 30 20 10 0 Gage R&R Repeat Reprod Part-to-Part

Response BY Part
%Total Var %Study Var 3

Percent

Part

351

352

Gage R & R

EMD STAT Simulator (2 and t tests)

created by: M.Shoen Davis, Erik W. Ferguson & Patrick M. Noonan boxes with data boxes have solution

Fill The

if Gage R & R > 30% or fails other tests FIX THE MEASUREMENT SYSTEM

Other Statistics

Six Sigma Overview

Step 4. Establish Process Capability

Step 4: What is the best @ status quo...

OTD to Dynacircuits (Direct)
100% 80%

% OTD
ST LT 0.52211 0.17181 2.78146 3.03888 2.66120 -2.33299 0.002706 0.001187 0.003893 99.6107 3893.15 0.95000 0.15234 0.32821 6.23593 0.32821 -2.33299 0.371378 0.000000 0.371378 62.8622 371378 1.09 1.04 0.96 0.92

Report 2: Process Capability for % opt

I and MR Chart
1.0 3.0SL=0.9827 Mean StDev 0.0 Observ. 0.6 0.5 0.4 0.3 0.2 0.1 0.0 0 10 20 30 40 3.0SL=0.5658 -3.0SL=0.06155 Z.USL Z.LSL Z.Bench Z.Shift P.USL R=0.1732 -3.0SL=0.000 Yield PPM P.LSL P.Total 0.5 X=0.5221

60% 40% 20% 0% May Jun Jul Aug

Capability Indices

Hisco Coshocton

Days to Replenish
30 25 20 21 Days GOAL 24 25 28

Potential (ST) Capability

Process Tolerance
0.48970 I I 0 I I I 1 1.41030 I

Actual (LT) Capability

Process Tolerance
0.00299 I I 0 I I I 1 1.04124 I

Cp Cpk Pp Ppk

Days

Specifications

Specifications

Data Source: Time Span: Data Trace:

15 10 5 0 May Jun Jul

Line 7 Cpk
Low er Spec

Aug

* Avg Days to replenish based on 21 day "pipeline"

Inventory Turns
24.98 25.00 20.00
0.35 0.40 0.45 0.50 0.55 0.60 0.65 0.70 0.75

23.30

Total Turns Annualized 21.45

# of Turns

15.00
8.10

15.00 10.00 5.00 0.00 May Jun Jul Aug

7.70 7.15

Short-Term Capability Cp CPU CPL Cpk Cpm * * 0.74 0.74 * Targ USL LSL k n 0.9 * 0.5 * 16.0 Mean Mean+3s Mean-3s s 0.609229 0.757676 0.460783 0.049482 %>USL Exp Obs %<LSL Exp Obs * * 1.36 12.50 PPM>USL Exp Obs PPM<LSL Exp Obs * * 13641 125000

Cp Cpk Ppk

Run Charts Histograms Box Plots Control Charts

Six Sigma Overview

Step 5. Define Performance Objectives

Step 5: Who is the best and why...

Benchmark Outside Market

EMD Simulator Proportion Probability Ho: Ha: OBSERVED PROPORTION complaints Pounds chi-2 data 62.000 10.000 2.880 50.000 33.000 8.000 1.225 40.000 3.000 1.000 0.800 5.000 2.000 1.000 1.800 5.000 0.000 0.000 0.000 0.000 100.000 20.000 6.705 obs expected obs expected obs expected obs expected obs expected obs expected factor White Black Red Yellow

Benchmark- Allied Signal/Polyclad

Handwritten LOT #

763211-22Y

Prepreg
of rows 1)#Describe # of columns Alpha Value 4 Ho: 1 Ha:0.1
95 EMD

D.F. 3

One Sample ------ One Tailed Test

Simulator

Actual Size sample Our lot #s Their PO# In cardboard on top of each skid Our Lot# and CofC on each sample

Certificate of Conformance/ Test Results

Cardboard Carrier for Sample

Tape on 3 edges to make an envelope shrink-wrap or plastic wrap around sample carrier

Certificate of Compliance Attached to the Cardboard

2) Confidence Level

Calculated alpha level Alpha level 70 0.1

0.05

TOTALS

Critical Value 6.251 Computed 6.705 1 3) # of tails Chi Acceptablity Reject Ho

4) Enter Standard Value of comparison 5) Enter sample data 1 60 2 66 3 70 4 74 5 66 6 80 7 92 8 100 9 95 10 80 11 70 12 85 13 14

Handwritten LOT #

Laminate
6) Compute AVG Std Dev Sample Size D.F. 7) Compute t-value 2.22 8) Critical t-value 78.17 12.73 12.00 11.00 9) Acceptability 1.795884 reject Ho

Hypothesis Testing: Chi-Square, t-test F-test

11x11 sample per lot Our lot #s Their PO# In a box, first off the truck, all samples for the 38 skids on the truck Our Lot# and CofC on each sample No More than 2 Lots per box

762203-11Y

Certificate of Conformance Test Report

11 x 11 sample of laminate

Certificate of Compliance + test results taped to the sample

Benchmark the Competition

Six Sigma Overview

Step 6. Identify Variation Sources

Step 6: Why arent we there yet...

PFD #4 WASTE TREATMENT OPERATION

WASTEWATER

Measurement

Manpower

LAMELLA

Machine
POLYMER MIX/HOLD TANK

INPUT SECTION

Barcode not working Lack of audit trail- non-lot specific at ownership of defect material PD/BOM ownership work centers Data entry procedures Computer Availability Wrong input QTY based on measure material movement procedures operators do not input input errors Supervision (audit) Supervision (knowledge)

PFD# 3 MANUFACTURE of the INSULATING MATERIAL MINERAL UNLOAD AIR CLASSIFIER BAGHOUSE

FLOCCULATION SECTION

CLEAN WATER TANK

LAMELLA SETTLING SECTION

FURNACE HCl NaOH DI WATER QUENCH

WASTE GENERATION

DI WATER
SLUDGE TO LANDFILL SANDFILTER

tie from error to cause top-down communication Report total transactions Scrap report BOM incorrect Large workstation size (DOCK) Operator timely input Metering of Acetone QC/Obsolete Material in inventory Large W/O size Supervision (routine) UOM (phantoms)

Raw Glass Inventory Errors

GRINDER WASTE GENERATION

POTW EAST LAGOON

WEST LAGOON

SLURRY PREPARATION

INSULATING MATERIAL PRODUCTION

WASTE GENERATION

Identified the select few

PREPARE ROLLS SHIP TO CUSTOMERS

Environment

Method

Material

Process Map Variation

Fishbone Diagram

Six Sigma Overview

Step 7. Screen Potential Causes

Step 7: What variables influence the gap...

Screening DOEs

Six Sigma Overview

Step 8. Discover Variable Relationships

Step 8: Finding the best settings...

Optimization DOEs

Optimization Equation

Six Sigma Overview

Step 9. Establishing Operating Tolerances

Step 9: Putting tolerances on knobs...

Defining the rules of the game!

Putting the boundarys around our xs

Six Sigma Overview

Step 10 Define and Validate the Measurement System on Xs

Step 10: Double check the measurement...

Gage Repeatability & Reproducibility Analysis:

Standard GRR (Long Form) NOTE: The defaults of the following worksheet are intended for 3 Oper, 3 Trials and 10 Samples (Parts). This worksheet is also flexible to less number of Oper, Trials and Samples Make sure you use the appropriate constants (D4, K1 and K2), if you use less number of trials or samples. Operator A B Sample # Trial 1 Trial 2 Trial 3 Range Trial 1 Trial 2 Trial 3 Range 1 5.70 5.70 5.70 0.00 5.75 5.75 5.75 0.00 2 4.20 4.20 4.20 0.00 4.25 4.25 4.25 0.00 3 0.40 0.40 0.40 0.00 0.50 0.50 0.50 0.00 4 1.70 1.70 1.70 0.00 1.75 1.75 1.75 0.00 5 1.80 1.80 1.80 0.00 1.75 1.75 1.75 0.00 6 1.60 1.60 1.60 0.00 1.50 1.50 1.50 0.00 7 0.70 0.70 0.70 0.00 0.75 0.75 0.75 0.00 8 1.50 1.50 1.50 0.00 1.50 1.50 1.50 0.00 9 0.00 0.00 10 0.00 0.00 C Trial 1 5.75 4.25 0.50 1.75 1.75 1.50 0.75 1.50 Trial 2 5.75 4.25 0.50 1.75 1.75 1.50 0.75 1.50 Trial 3 5.75 4.25 0.50 Range 0.00 0.00 0.00

GageR & R of 10.12% 1.75 (Xbar/R) 0.00 Gage R&R for Data 1.75 0.00
1.50 0.75 1.50 0.00 0.00 0.00 0.00 0.00

Gage name: Date of study: Reported by: Tolerance: Misc:

Xbar Chart by Operator

1 2

Operator*Part Interaction
3.0SL=2.815 2.5

2
2.22 2.20 0.02 2.21 1.71

Ra Rb Rc Sum R

0.00 0.00 0.00 0.00 0.00

# Trials 2 3

D4 3.27 2.58

(R) x (D4) = UCLr UCLr = 0.00

Tolerance

UCL 0.25

LCL -0.25

Max X Min X X Diff Mean 1 Stdev

Measurement Analysis
Repeatability - Equipment Variability (E.V.) E.V. = (R) x (K1) E.V. = 0.00 Reproducibility - Appraiser Variation (A.V.) A.V. = ((Xdiff * k2)^2 - ((E.V.)^2/(n x f)))^.5 A.V. = 0.05 Repeatability and Reproducibility (R&R) R & R = ((E.V)^2 + (A.V.)^2))^.5 R&R= 0.05 Trials K1 2 4.56 3 3.05

% Tolerance Analysis
% E.V. = 100((E.V.)/(Tolerance)) % E.V. = 0.00

R Chart by Operator
1

Fully Acceptable Measurement System -3.0SL=0.9347 for the measurement of downtime.

2

X=1.875

Average

0.00 0.00

0.00 0.00

Sample Mean

Totals Daily Ave. Daily Std. Final Ave.

17.60 2.20 1.81 Xa

17.60 2.20 1.81 2.20

17.60 2.20 1.81 Ra

0.00

17.75 2.22 1.82 Xb

17.75 2.22 1.82 2.22

17.75 2.22 1.82 Rb

0.00

17.75 2.22 1.82 Xc

17.75 3 2.22 1.82 2.22

17.75 2.22 1.82 Rc

0.00 0.00 0.00

Operator
1 2

2.0

1.5

Part
3

351

352

Response BY Operator

Trials 2 K2 3.65 n = number of parts f = number of trials

3 2.70 8 3

% A.V. = 100((A.V.)/(Tolerance)) 1.0 % A.V. = 10.12

Sample Range

1.5

3.0SL=1.634

2 R=0.5000 -3.0SL=0.000 1

0.5

% R & R = 100((R&R)/(Tolerance) % R & R = 10.12 0.0

Gage R & R on the Xs

Oper

Components of Variation

Response BY Part
%Total Var %Study Var 3

Identifying if how we measure downtime is accurate!

Percent

100 90 80 70 60 50 40 30 20 10 0

1 Gage R&R Repeat Reprod Part-to-Part

Part

351

352

Six Sigma Overview

Step 11. Determine Process Capability

Step 11: Finding our new best...

Report 2: Process Capability for % opt

I and MR Chart
1.0 3.0SL=0.9827 Mean StDev 0.0 Observ. 0.6 0.5 0.4 0.3 0.2 0.1 0.0 0 10 20 30 40 3.0SL=0.5658 -3.0SL=0.06155 Z.USL Z.LSL Z.Bench Z.Shift P.USL R=0.1732 -3.0SL=0.000 Yield PPM 62.8622 371378 1.09 1.04 0.96
Cp * * 0.74 0.74 * Targ USL LSL k n 0.9 * 0.5 * 16.0 Mean Short-Term Capability

Line 7 Cpk
Low er Spec
ST 0.95000 0.15234 0.32821 6.23593 0.32821 -2.33299 0.371378 0.000000 0.371378 LT 0.52211 0.17181 2.78146 3.03888 2.66120 -2.33299 0.002706 0.001187 0.003893 99.6107 3893.15

Capability Indices
X=0.5221

0.5

P.LSL P.Total

Cp Cpk
0.35 0.40 0.45 0.50 0.55 0.60 0.65 0.70 0.75
0.609229 0.757676 0.460783 0.049482 %>USL Exp Obs %<LSL Exp Obs * * 1.36 12.50 PPM>USL Exp Obs PPM<LSL Exp Obs * * 13641 125000 CPU CPL Mean+3s Mean-3s s Cpk Cpm

Potential (ST) Capability

Process Tolerance
0.48970 I I 0 I I I 1 1.41030 I

Actual (LT) Capability

Process Tolerance
0.00299 I I 0 I I I 1 Data Source: Time Span: Data Trace: 1.04124 I

Cp Cpk Pp Ppk

0.92

Specifications

Specifications

Six Sigma Overview

Step 12. Implement Process Control

Step 12: Locking down the changes...

g
GE Electromaterials
Step 12: Implement Process Controls

FABRICATION YIELD

M A

Controls Implemented to Maintain Level

1) Business decision to be made by the Champion (Manufacturing Manager) for any order which CPV will be greater than 1% 2) All loads that have a QC-40 (Dispositioned) are coded at scheduling to ensure appropriate financial category for loss 3) All orders that customer is known to pay for the yield loss are removed from the CPV equation (GETEK is biggest pay-off) 4) All orders are tested for patterning regardless of cutting history 5) Implemented weekly Manufacturing Dashboard to ensure process maintains in control.
Notify Customer Service

Final CPV Process

Send Drop to Service Center/ Prime Mat'l Inventory
Y es

Usable Drop
No

Cut on FAB Line

Salvage Cut on FAB Line

Y es

Cut on FAB Line

Y es

No

Mfg Mgr Approval

No

Yield Loss < 1%

No

Receive Order

Cut @ Service Center

Y es

No

Cut From Drop-off

No

Perfect Yield

No

Cut from QC-40

No

100% Pattern

No

Yield Loss Paid for

Y es

Y es

Y es

Y es

Y es

Cut @ Service Center

Cut from Drop-off

Cut on FAB Line

Cut on FAB Line: Ensure Coded for Scrap Loss

Cut on FAB Line

Cut on FAB Line: Notify Finance/ Spreadsheet

e GEElectromaterials
Manufacturing 2Q est

Manufacturing Dashboard

Defined Process Checks

Cut Piece Variance (July 97)

0

M A

Now
15 30

-10 -20

50

$ -36,326 = -1.2%
-100 -175 Goal

l Goa -30

$-10,286 =-.4%

100 150

Now

Cut Piece Var $M FW 28

2Q by FW in $M
150 100 50 0 -50 -100
14 16 18 20 22 24 26 28

Cut Piece Var (Gross) $ M July

100

MAJOR ISSUES $ 1,421 NON-PATTERNABLE THIN M/L $ 10,157 GETEK CPV FW28 $ 15,825 GETEK credit: JUNE $ 8,372 PAID BY CUST. $ 6,640 QC MATL USED $12,331 SALVAGE DROPS USED

FY97 by Month (NET) in $M

2Q Goal: $448M $403M stretch

0 -100 -200 -300

Actual Goal ADJUSTED

May

Action Items
Item Recapture QC loss GETEK Credit Recapture CPV Paid by Cust. Owner D. Gonzalez/J. Lee J.Lee/T.King D.A.G./J. Lee

QTD $-36,326 JUL= -36K AUG= SEP=

Sep

Timing Monthly Weekly Monthly

$ (%) Impact $14,308 MTD $15,825 QTD $13,916 MTD

Status/Issues Pending EOW Close Pending EOM Booking Pending EOM Booking

Internal Dashboard Created

Nov

Jan

Mar

Jul