Six Sigma Project $86,000 Cost Reduction in 10 Months

Description

I’m sure you’ve heard of Six Sigma and the DMAIC (Define-Measure-Analyse-Improve-Control) methodology but have you ever seen a completed project before?  Here’s your chance.

The Six Sigma Project – Increasing Laptop Reliability is a complete Six Sigma DMAIC Black Belt project that was submitted to a Master Black Belt for certification and eventually accepted.

This Six Sigma project demonstrates how laptop failures were identified, and controls put in place to represent $86,000 savings in ten months.  This template can be reused for other similar projects and the savings can be applied in other scenarios.

This product includes the following complete files:

• Microsoft Power Point (45 slides) – Project charter and presentation
• Microsoft Excel (13 tabs) – project data
• Minitab data file (.mtw)

Six Sigma Project Overview

Acme Laptop Company has been manufacturing and selling laptops for nearly a dozen years.  They successfully launched two flagship models, the DEVICE, and the GADGET, keeping costs and after-service warranty expenses low and in control.

After launching their third model a little over a year ago, the WIDGET, their quality assurance team quickly summoned help from their in-house Six Sigma Black Belt as they could not figure out why there were so many customer returns in the first year since the product launch.  In addition to the customer pain, the company was incurring hundreds of thousands of dollars of additional, unbudgeted expenses.

All design validation and mistake-proofing devices were put in place and all the WIDGET laptops met the stringent final QC requirements such as did the previous models but the WIDGET continued to fail early into the warranty coverage period, incurring additional costs for replacement units and freight to get the replacements to the customers.

How did the Six Sigma Black Belt approach the problem? What findings came about?  What permanent corrective solution was put in place?

Six Sigma Project includes the following:

Define Phase

• Project Charter
• Team Roster
• VOC
• Graphical Data
• SIPOC
• Define Phase Review

Measure Phase

• Process Map
• Cause & Effect Matrix
• Preliminary FMEA
• MSA
• Baseline Capability Analysis
• Measure Phase Review

Analyze Phase

• Hypothesis Testing
• Analyze Phase Review

Improve

• Brainstorming
• Final FMEA
• Implementation Plan
• Final Capability Analysis
• Improve Phase Review

Control

• Control Plan
• Control Phase Review
• Project close-out

 

Instructions

As soon as you’ve completed payment in our secure, online store, you’ll receive a download link (valid for 7 days) to download a .zip file.  Simply extract the contents and there you go.

Should you have any questions prior to your online purchase, please feel free to ask them at [email protected], where we’ll always respond in the same business day.

Prerequisites

You’ll need a valid license for Microsoft PowerPoint and Excel in order to view the files.  The files are in their native form so you may adapt them to your specific needs.