Measure Phase Blog - Feb 2016

Measure Phase Blog - Feb 2016

Data Collection Process Map

The Measure Phase of DMAIC involves how the process data is gathered, determining what is important, studying the collected data and defining the baseline process capability. For the process X assembly line, there is a data collection method in place which allows the Production Administrator to obtain accurate Output and Reject figures for each stage in the process line, this can be used to obtain historical data to find baseline figures and to accurately keep track of future data. This data is gathered using the method shown on the process map to the right;

The gathered data was studied and the Output, Rejects, Yield and Sigma Level were calculated using the formula below; (Please Note the following, Number of Opportunities for defects = 8, Number of units 1,180,000 and the Sigma Level was obtained via conversion tables from the DPMO)

The information obtained from the data and the resulting calculations is shown in the table  to the right;

This table is extremely useful as it gives us clear information on each process and an overall indication of how the combined processes are performing. This will be of benefit when the Analyse phase begins.

A Pareto chart was generated for Process 3; this chart is useful as it gives us a clear  indication of why the parts have been rejected and will be a useful metric in the Analyse phase.

The tools that were used in the Measure Phase have allowed an accurate baseline for the project to be calculated, the data collection method shown in the above process map will be used throughout the duration of this project. As a result of the Measure Phase the 'Project Statement' and the 'Objective Statement' have been updated to the following;

'Project Statement; The product X process has an average reject rate from Jan - Dec 2015 of 4,945 parts p/m. This corresponds to DPMO = 6285. Which indicates a Sigma Level of  3.9 sigma'

'Objective Statement; Reduce the DPMO to <3140 within 6 months, to do this  scrap must be reduced by 50%. This is around 2,472 rejects p/m. If a DPMO of 3140 is achieved, this will allow a Sigma Level of 4.2 sigma to be achieved'