iSixSigma

Joe Wojniak

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  • #243247

    Joe Wojniak
    Participant

    @michaelcyger – Hi Michael, I did complete a project as part of the certification process, in addition to several weeks of training and taking an exam.  The project focused on implementing in-process test at a supplier.  There were a couple alternatives for this in-process test, some providing more test coverage but were also more expensive.  The project identified via a reliability model and Monte Carlo simulation that in-process failures were likely to have very low occurrence rates, so the more expensive test didn’t make sense given the costs of implementation vs. the expected benefits.

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    #241365

    Joe Wojniak
    Participant

    Hi Kamal,

    it’s great that you’re interested in Lean Six Sigma.  I don’t think a Phd is necessary.  Depending upon the improvement tools and methods that you choose to use, some statistical knowledge is helpful.  You can also implement Lean Six Sigma without statistics, but basic analytical techniques are necessary.  I recommend SSD Global’s online program.  You can attend training sessions in person or online.  You can find more information here, I tried the link and there seems to be some kind of problem with the website (Sunday 8/25/19).

    https://ssdglobal.net/group-training-oppourtunities/

    Since the website is having a temporary issue, I recommend the book Leaner Six Sigma, written by SSD Global’s CEO Terra Vanzant-Stern.

    https://www.amazon.com/Leaner-Six-Sigma-Make-Lean-ebook/dp/B06Y1T9WG7/ref=cm_wl_huc_item

    Black Belt Certification is a great way to get started in Lean Six Sigma.  If you anticipate that you’ll be teaching others, you may want a Master Black Belt Certification.

    Good luck! -jw

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    #241046

    Joe Wojniak
    Participant

    Hi @AlonzoMosley- I’m not sure what ATC329, ATC390, and BHG350 are.  I like using Is/Is Nots because it is a great method for determining what information is meaningful to the problem and what is not.  Thanks for adding to this post!

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    #239751

    Joe Wojniak
    Participant

    Thanks! These are great suggestions.

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    #238993

    Joe Wojniak
    Participant

    @ahance – you may want to look into Scientific Injection Molding (SIM) before starting your SPC implementation. Here’s a link:
    https://www.scientificmolding.com/index.php

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    #238957

    Joe Wojniak
    Participant

    @johnny1287 – here are some well-known companies that have used Six Sigma for a multitude of projects. DMAIC projects tend to be “make the process better” type of project. DMADV projects tend to be “make the product design better”, you can also search for DFSS (Design For Six Sigma) projects. Here’s a list of prominent companies: Motorola, GE, Texas Instruments, Covidien/Medtronic, and Eastman Kodak. If you search for Six Sigma Consultants, they’ll generally have their “pedigree” stated in their bio or resume (if you did a LinkedIn search for Six Sigma practitioners.) You can also search for Lean Sigma or Lean Six Sigma. Here’s an article that mentions many large corporations and which methodology they are using: https://formaspace.com/articles/manufacturing/best-framework-model-for-company/

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    #238857

    Joe Wojniak
    Participant

    Here are some good resources. Lean Six Sigma for Good is also free. This is good introductory material, while showing that what can be improved is simply a matter of choice.

    http://www.leansixsigmaforgood.com/

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    #238888

    Joe Wojniak
    Participant

    Many scanners have OCR capability, or you can look into specialized OCR software to get better performance. A quick search found the following-
    https://www.anysoftwaretools.com/convert-scanned-pdf-to-excel/
    https://www.simpleocr.com/ocr_to_excel/
    It’d be great to hear what you decide to use, and how well it works.

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    #238889

    Joe Wojniak
    Participant

    I’m not sure if my previous reply will post, so this may be a duplicate:
    OCR software is needed to convert the hand-written paper to a data format. Hand-writing needs to be pretty clear and simple, no cursive. Here are some links that show up from a quick search:
    https://www.simpleocr.com/ocr_to_excel/
    https://www.anysoftwaretools.com/convert-scanned-pdf-to-excel/

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    #238878

    Joe Wojniak
    Participant

    These are good directions, I’d also suggest talking to management about their immediate and mid-term goals. Identifying goals & barriers will help when deciding which improvements to tackle. Quick wins and visible successes are a great way to start and to build momentum and acceptance. As @andy-parr has stated, you have a wonderful opportunity! Good luck!

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    #238858

    Joe Wojniak
    Participant

    These are great ideas, weighing the pallets, using counting scales to weigh small loose bulk items also helps. In addition, determining where in the sequence the miscount occurs can also help (i.e. when is the item or box scanned as picked?)
    1. Scan, pick, load onto pallet -> item may be scanned but not picked, resulting in a missing case.
    2. Pick, scan, load onto pallet -> All picked items are scanned. Hopefully, there is little opportunity for picked items to not be placed on the pallet?
    3. Use a pallet jack to move the pallet to the pick locations (vs. bringing cases to the pallet on the shrink wrapper)
    4. Preventive: ensure pick orders are equivalent to 1/3, 2/3, 3/3 of pallet (if there are 3 layers of cases on the pallet.)

    Problem-solving method: use fish-bone diagram / Ishikawa diagram to brainstorm possible causes of missing cases.

    Validate potential solutions: did the problem get fixed? what fixed it?

    • This reply was modified 2 years, 4 months ago by Joe Wojniak. Reason: add hyperlink to fish-bone diagram explanation
    • This reply was modified 2 years, 4 months ago by Katie Barry.
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    #238845

    Joe Wojniak
    Participant

    Hi Tamela, it’s great that you’re pursuing a Master’s in Applied Statistics! I’ve been using Minitab for years, I’m sure you’ve got a great background from working there. SPC is an interesting topic- I got my first job in Quality implementing SPC. I’ve seen interest in it rise and fall– depending upon the industry. If the company is primarily a contract manufacturer and are essentially selling their service of manufacturing, they may be interested in SPC. For other manufacturers, high volume, low margin products where a small number of defects would prevent achieving any profits are most likely to being interested in SPC. The emerging area for statistics seems to be in ‘Big Data’ and using R. Good luck!

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    #238671

    Joe Wojniak
    Participant

    This is definitely an interesting topic. We tend to remember failures and negative consequences longer than successes or pleasant experiences, although pleasant experiences are motivating just not memorable! I would suggest that the work groups have knowledge about what to control in order to get the desired outcome- and therefore no significant scrap for decades. Talking to these people and understanding what they do and also seeing what they do will likely lend insight. Is this called a Gemba walk?

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    #238656

    Joe Wojniak
    Participant

    Hi Karthik, deciding whether 99% is good enough or not can be difficult. I’m not familiar with the acronyms you’ve used, I’m guessing UAT is unit acceptance test and BOTS are SW bots? Anyway, some kind of automation (whether a robot or a SW bot the issue remains the same.) In hindsight, you seem to be saying that the 1% customer escalation rate initiates a technical support “damage control” activity- 100% inspection. I’ve heard it said that 100% inspection is 80% effective… whether true or not, it illustrates the point that service or product quality cannot be inspected in. It takes some effort, but you can assess the total cost of quality of the 1% customer escalation rate and it’s effect both on customer satisfication and the lost productivity resulting from efforts to contain a problem that may or may not be there. A key consideration is that SW defects don’t occur randomly, but are the result of specific combinations of inputs. The difficulty is in presenting enough variation in the inputs to determine whether the BOTS can be made to be robust to this variation and deliver the desired input. It’d be great to hear more about your application and I hope that some of this is close to the mark.

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Viewing 14 posts - 1 through 14 (of 14 total)