• Hi, just to 2nd Eric’s comment on Discrete Event Modeling / Process Simulation being very useful for this. Drop me an email and I would be happy to show you some examples using SIMUL8. 3 years, 1 month ago

  • Hi Jodean,

    This is a great question – Lots of new SixSigma users will have questions with the math and once you see this, its actually pretty straight forward:

    First, lets swap out the numbers to easier values. What if we had 500 defects per 1000 opportunities. We would get a defect rate of 500/1000 = 0.5 , i.e. the defect rate per single…[Read more]

  • Running the numbers we get these distances:

    Sigma Level DPMO % of defects Avg. Distance in Miles that first defect occurs
    1 690,000 69.00000% 1.449
    2 308,537 30.85370% 3.241
    3 66,807 6.68070% 14.968
    4 6,210 0.62100% 161.031
    5 233 0.02330% 4291.845
    6 3.4 0.00034% 294117.647

    On a standard scale the first 4 are all very close together so…[Read more]

  • Hi Chris, I think this is a great thing you are doing and you sound like you would be an awesome buddy to work with. One idea I had was to paint out something to do with the difference that Six Sigma makes to Aircraft reliability. You could paint out an image that plots the distance that an aircraft can fly if its reliability and that distance was…[Read more]

  • Neat project; I can attest to some of the difficulties of BF timings, up to our eyeballs right now with baby number 3!

    As per comments above, storage capacity could be key here. Although it would be good to know more. From reading is it correct to assume that the tricky part here is that there is no way of knowing which Mothers will be able to…[Read more]

  • What tools were used to make the measurements? 2cm is not an untypical error if measuring across a large warehouse. If tape measures then bad alignment or being inconsistent with push/pull leeway could easily account for this. 3 years, 9 months ago

  • Hi Chris,

    Good question, I would also consider a 3rd options to count as failures / missed opportunity / rework at both stations? The key question for me is do we lose time at the 2nd station?

    If the answer is no, then the 2nd station is acting as a QC / inspection step and I would lean towards counting as rework for station 1 only.

    If the…[Read more]

  • Oh wow, I beat Mike to your post. This page is a good guide:

    3 years, 10 months ago

  • I agree 5 whys is a guide but you will need to go deeper sometimes. What defines the stopping point is when there is a commonality on the causes. A Fish bone ( then helps to see that commonality and determine what to target. 4 years, 2 months ago

  • Mike, I 100% agree. I find tollgates make sense for DMAIC and less so for how I do Lean (although often I’m implanting Lean as a subset of DMAIC), with Lean its mainly 5S Kaizens that naturally flow from 1 into the next. That’s why I am interested how Roy is defining his Lean steps here. 4 years, 2 months ago

  • Hi Roy, interesting question. What do you define as your LEAN stages? 4 years, 2 months ago

  • Hi Brunehilde,

    This may be a tricky one. Could you describe this a little more, I’m not sure if I understand where internal and external activities sit in relation to the cycle time?

    Is it the case that the inspection work takes up so much of the cycle time so that there is not enough time to make an external setting for the next part, and…[Read more]

  • Hi Doug, I may be able to assist you with a trying a Process Simulation, i.e. a model where we can map out the stages of the process, the variation in X and the rules around how this effects return. We could try using a Monte Carlo approach to allow you to model the variation in X over multiple runs to determine the likelihood of an outcome.

    Is…[Read more]

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  • Yes, sounds like Monte Carlo would be a good fit here. I’d be happy to link you to an online SIMUL8 Simulation example that can do this. Can you explain more about the success criteria and the way that you want the randomization to occur? I.e. why is +-+ a fail and +– is a success? Should the variation in occurrence of these be totally random in…[Read more]

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