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trouble finding X predictors

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  • #33639

    agentofchange
    Participant

    my project is somewhat stalled in the analyze/improve area because of some uncertainty of implementing our solution. raw materials has to fill a certain demand for production to complete jobs at the correct quantity. On average (mean), production uses about 7% extra material per job for set-up/common cause issues. The problem is the standard dev. at 4%. I can’t find any predictors or relationships as to why sometimes more than 7% material is used? I feel like I have analyzed everything without success! If raw materials issues 7% extra for all jobs then a lot of them will come up short from the needed quantity. He currently issues roughly 15% over but it is costing us for all the excess finished parts lying around. (the deliverable for the project is to reduce these parts)What am I missing here? Any thoughts on this.

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    #91974

    Srinivas R
    Member

    You must have missed some important segmentation factors. I would advise you to do a thorough brainstorming exercise with all the stakeholders to identify these factors. With the given data, I cant think of anything else.

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    #91981

    Bob Peterson
    Participant

    Agent:
    Perhaps you could consider attacking the 4% standard deviation rather than the 7% mean.  I have found this approach to be quite effective.  Should the 4% SD come about because of inability to quantify the parts supplied, then it becomes a measurement system issue.  Feel free to drop me a note at [email protected] if I can advize further.
    Bob Peterson

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    #91987

    Banking Engineer
    Participant

    Agent,
    Material in = material out, so find out where the raw material is going.  Sometimes you make extra good parts – what happens the rest of the time?  Look for waste (swarf, spills, flash, etc.) and bad parts.  The clues for what is causing the 4% will be in where the raw material went. Bad part dimensions, excess process scrap, material spills should all be part of your PFMEA (process FMEA), so you should have the x’s to investigate already – but also revisit brainstorming as was suggested once you know where the raw material is going – your PFMEA may have missed something, or your process may have been changed.
    Once you find the way to reduce the 4% variation, you may also find the way to further reduce the 7% mean.  Good luck.

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