IMPLEMENTING LEAN SIX SIGMAA CASE STUDY IN CONCRETE PANEL PRODUCTION

PRESENTED BY:SANOBAR HANIF

ROAD MAP TO PRESENTATION

CASE BACKGROUND SIX SIGMA CASE STUDY

CASE BACKGROUND

The owner company is developing the Phase II of the Jubail Industrial City in

Saudi Arabia. Part of the Jubail Phase II development is to provide 405 villas for the community. Due to the speed and

efficiency in production and installation, it was decided to construct the villas using precast wall and floor panels.

WHAT IS SIX SIGMA??????Total Quality Management

Zero defects

Six SigmaSix Sigma

Quality Control

•Six sigma is a business statistical Strategy.•The Six sigma was founded by Motorola in the 1970s.•Bill Smith, “Father of six sigma” introduce this quality improvement Methodology to Motorola.

WHAT IS SIX SIGMA??????

WHAT IS SIX SIGMA??????

SIX SIGMA METHODOLOGY

KINDS OF VARIATION

Y: output

f: Function

X: Variables that must be controlled to consistently predict Y

COMMON CAUSE VARIATIONSPECIAL CAUSE VARIATION

PROCESSXn Y

SIX SIGMA PERFORMANCE INDICATOR

CP(PROCESS CAPABILITY INDEX)

In implementing Six Sigma principle, CTQ is a main indicator in the phases of DMAIC.

Cp = (USL – LSL) / (6 x STDEV)

CASE STUDY

PROBLEM STATEMENTThe contractor was 25% behind the

schedule.

SIX SIGMA TEAMBechtel’s Six Sigma Black Belt team.

CASE STUDY

PRIMARY METRIC

The ‘Number of Exterior Insulated Panels Delivered to Construction Site per Day’. The current state baseline production rate was 18 panels/day, and in order to recover the schedule, 75panels/day was targeted.

CTQThe variation of panel production as a (CTQ) to measure the performance indicator of Six Sigma system.

CASE STUDY

GOALS Improve productivity Establish causes for delay Operate at takt time intervalAchieve all critical milestones per contract

terms and conditions

CASE STUDY

VALUE STREAM MAPPING

KAIZEN

TAKT TIME

CONTROL CHARTS LEA

DE

RS

HIP

PR

OC

ES

S F

LOW

WA

ST

E A

ND

VIS

UA

L C

ON

TR

OL

ST

AN

DA

RD

WO

RK

LOG

IST

ICS

X1 X2 X3 X4 X5

TOOLS AND CRITICAL X’s

CASE STUDY

VALUE STREAM MAPPING is a lean-management method for analyzing the current state and designing a future state for the series of events that take a product or service from its beginning through to the customer

Takt time derived from the German word Taktzeit, translated best as meter, is the average unit production

time needed to meet customer demand

Kaizen (改善 ?) for "good change“

Control charts, are tools used to determine if a manufacturing process is in a state of statistical

control .

CASE STUDY

ACTIONS FOR CRITICAL XIMPROVE LEADERSHIP Appoint general superintendent Hire full time Project Quality EngineerPROCESS FLOW Dedicate two cranes for production area Start use of ready-mix trucks for grey concrete Add night shift to recover scheduleWASTE CONTROL Reconfigure stockyard for better access and control Reduce inventory level Status inventory and develop Electric Inventory Logs to track storage and deliverySTANDARD WORK AND IMPROVE LOGISTIC Prepare a list of standard activities with clear roles, responsibilities and accountabilities Measure cycle time and reduce lead time by eliminating waste

CASE STUDY

TACKLING OVER THE CRITICAL X’SThe Production rate 75 panel/day was achieved

CASE STUDY

Both Six Sigma and Lean are strong production management tools and the combination complements each other. Lean in principle eliminates anything that doesn’t add value to the customer and achieves reliable workflow. On the other hand Six Sigma aims to control and reduce the variations by understanding the root cause.The methodology of Lean Six sigma was effective in reducing variability of daily panel production rate.

Thank you !