Problem statement
The current sampling process for in-coming raw materials wastes resources and results in production delays. Of the batches sampled to date, an average failure rate of 30% (n=40) is observed.
Objective
The objective of this engagement was to prevent delays in production and minimise impact to operational areas. This would be achieved by streamlining and error proofing the process, and creating a manufacturing pull-based system for the sampling/testing of materials
Lean Ireland consulting/training work
The project was completed by a cross functional team of client employees, who undertook two-day Certified Lean Six Sigma Yellow Belt Training with Lean Ireland. The training provided the DMAIC (define, measure, analyse, improve and control) project framework for the team, plus a varied toolset to enable the team to work through the project phases. The Lean Ireland facilitator provided project mentoring on a regular basis throughout the project lifecycle.
The certified lean six sigma yellow belt (CLSSYB) training course is facilitated by Lean Ireland to ISO 13053-1 standards. Courses may contain additional content in line with client preferences. The total consultant involvement was approximately 6 days, including onsite training, online project mentoring and certification for a CLSSGB cohort of 12 candidates.
Detailed results of the client work
The yellow belt team used the lean six sigma DMAIC process and toolset to improve the process. In the Define phase the Yellow Belt team completed a gemba walk, a summary and detailed process map and a voice-of-the-customer exercise.
This identified several failures in the process to be quantified and root caused. A Fault vs. Fix matrix in the Analyse phase enabled the team to identify a suite of improvements to online applications and standard operating procedures (SOPs). Online sampling forms were error proofed and a group mailing list created for sampling updates.
The revised process flow
- had 18% fewer steps
- reduced the error rate by 91%
- reduced the average sampling time by 45% and
- reduced the resources required from 3 to 4 people to 2 to 3 people, depending on the sampling procedure.