SIX SIGMA PROJECT
BLACK BELT
BILAL MASOOD
Project title
To determine the defects in the paints filling units, reduce waste, reduce low quality and
suggest the recommendations.
DEFINE PHASE
MEASURE PAHSE
ANALYSE PAHSE
IMPROVE PHASE
CONTROL PHASE
DEFINE PHASE
Project title
To determine the defects in the paints filling units, reduce waste, reduce low quality and
suggest the recommendations.
Executive Summary
To reduce the waste in any industry is the most important factor, The paint industry is facing
many problems related to the paint wastage and poor quality related to some products. This
may lead to time, resources and finance wastage. So, it is important to reduce the wastage,
improve the quality of the product and increase the revenue. This will also make the customers
satisfied with high quality product.
Project Charter
Problem Statement
PAINT WASTAGE IN THE PAINT INDUSTRY AND TO REDUCE THE LOSS OF QUALITY
Goals
Financial impact
Team
Stakeholder Analysis w/ Stakeholder Commitment Scale
Communication Planning Worksheet
Audience media purpose Key owner frequency Notes Sr
message/Topic & #
of discussion status
Employees Video Motivation Motivations Very 1
conference high/daily
Management Presentations Improvement information Presentation Low/monthly Funds 2
Video
conference
3Technical Reports Defects Technical Medium Error 3
removals defects removal /high/after 2-
managers 3 days remove
CTS Summary
Project Plan
Supplier-Input-Process-Output-Customer (SIPOC)
Summary of Next Steps
MEASURE PAHSE
MEASURE PHASE
Project title
To determine the defects in the paints filling units, reduce waste, reduce low quality and
suggest the recommendations.
Executive Summary
To reduce the waste in any industry is the most important factor, The paint industry is facing
many problems related to the paint wastage and poor quality related to some products. This
may lead to time, resources and finance wastage. So, it is important to reduce the wastage,
improve the quality of the product and increase the revenue. This will also make the customers
satisfied with high quality product.
PRATO CHART
ANALYSE PAHSE
Project title
To determine the defects in the paints filling units, reduce waste, reduce low quality and
suggest the recommendations.
Executive Summary
To reduce the waste in any industry is the most important factor, The paint industry is facing
many problems related to the paint wastage and poor quality related to some products. This
may lead to time, resources and finance wastage. So, it is important to reduce the wastage,
improve the quality of the product and increase the revenue. This will also make the customers
satisfied with high quality product.
Cause & Effect Analysis or Why-Why Diagram
Histogram/Graphical Analysis
Process Analysis (including Statistical Analysis)
Eight (8) Wastes
Cost of Poor Quality
Failure Modes and Effects Analysis (FMEA)
Summary of Next Steps
IMPROVE PAHSE
Project Title
To determine the defects in the paints filling units, reduce waste, reduce low quality and suggest
the recommendations.
Executive Summary
To reduce the waste in any industry is the most important factor, The paint industry is facing
many problems related to the paint wastage and poor quality related to some products. This
may lead to time, resources and finance wastage. So, it is important to reduce the wastage,
improve the quality of the product and increase the revenue. This will also make the customers
satisfied with high quality product.
Design of Experiments-DOE
Define main goals
To determine the defects in the paints filling units, reduce waste, reduce low quality and suggest
the recommendations.
Factors
Controllable
• The Sop, design process and process improvements
• Using the lean tools, the defects and wastage can be reduced and are controlled factors
Uncontrollable
• The data has the variance and the defects in the paint boxes/cans are recorded variably
• Raw material defects are uncontrolled factors.
• Employees less motivated and non-serious behavior is uncontrolled factor
Experimentations
Record data
• Collect the data by the tables and charts
• The employees experience
• Supervisors
• Self-data collection
• Each time the data is taken on wastage and defect on the box/cans
Arrange data
Arrange the data in the form of graphs and tables as shown below
Statistical analysis
Quality Function Deployment (QFD)
Improvement Action Plans
Recommendations for Improvement
Revised Process Maps
Revised Statistical Analysis
Summary of Next Steps
CONTROL PAHSE
Project title
To determine the defects in the paints filling units, reduce waste, reduce low quality and
suggest the recommendations.
Executive Summary
To reduce the waste in any industry is the most important factor, The paint industry is facing many
problems related to the paint wastage and poor quality related to some products. This may lead to
time, resources and finance wastage. So, it is important to reduce the wastage, improve the quality
of the product and increase the revenue. This will also make the customers satisfied with high
quality product.
Control Plan
The industrial process is ever needing the controlling in better way, there are many methods used
to control the industrial process according to the customer requirements.
• Procedures
There are certain procedures, which can be adopted to increase the control over the process,
these are as follows
1- SOP’s: by using the SOP’s one can control the process in better way with high outputs.
The sop’s are the set of guide lines and procedures to be adopted to do the process is
better manner. These are actually the standards of the process, which can help others to
do the process in the accurate way. The sop’s are the back bone of any industrial process
like in the paint industry
2- Control charts: these are the set limited adopted to operate the process in the desired set
points. So the speed and other control charts for the paint process equipment’s can
operates in the desired set of operating conditions to get the high out puts
3- Continuous improvement: The CPI is PDCA, in which manager take the necessary
steps to provide the continuous process improvement and remove the defects and waste
from the system like in the paint industry. The paint industry is the unit process industry
and it can has many units or boxes with defects.
4- Change management: The change in any system is delt with the opposing force like
many old employees were opposing the automation 4.o. So to counter this problem the
training is most important factor.
5- Audits : there are two types of the audits
Internal audit: The internal audit is performed by the employees itself
External audit: The external audit is performed by the third party in the system.
Customers;
Customer satisfaction: The any industry, which completes its process, depends upon the
customer satisfaction. The satisfied customer is the success of the system.
The kano model is used to determine about the satisfaction of the customers
Customer feed backs: to improve the process the customer feedback is required, so the sales
persons are always there in the industry like paints process, to check the quality of the paints and
the paints performances.
Customer feed back system; the industry process always makes a room for the customer
feedback process as follows
1- Calls
2- Survey
3- Meeting
4- Seminars
5- Interviews
Removing errors from system
• Risk analysis & hazard identification:
• Corrective actions: The corrective actions are always needed to remove the defects
from the system
• Root cause analysis: This tells use about cause of the problem
Dashboard/Scorecard
Mistake Proofing Measures
There are many methods used for the mistake proofing, few are as follows.
Coding: when the any chemical batch enters the paint or any other industry, it is given a certain code, this
helps in many ways, like removing errors in the system, The whole industry uses these codes for the
production process.
Documentation: All the process in the industry is done on documentation, The inventory system to the
production, finance and management, all the systems are done on the documentations.
Labeling: All the process chemicals in the paint industry are labeled with codes, such that the whole
industry adopts that process. The labels help in determining the types of chemicals and precaution
measures to be taken for that system.
Software packages/ERP/SAP: the software packages help to interconnect the department and the stake
holders of the system. If the software data is updated at one department, it can be seen by other section of
the system.
SOP’s: by using the SOP’s one can control the process in better way with high outputs. The
sop’s are the set of guide lines and procedures to be adopted to do the process is better manner.
These are actually the standards of the process, which can help others to do the process in the
accurate way. The sop’s are the back bone of any industrial process like in the paint industry
Visual signs: in the paint and chemical industry, the visual signs are used to continuously remind the staff
to adopt the process adopted by the industry.
Devices and instrumentation/IPC: in the paint and chemical industry the process is controlled by the
devices, these devices are instrumented controlled systems. Like level, flow and heat-controlled devices.
The automatic shutdown system.
Training systems
• On job training: This process is mainly adopted in the paint industry, where the new
employee or old employee is given the training during the job. This is very good method
to give the training with practical work.
• Off job training: there certain sessions take place in which the training is given in the
classes
• Seminars: The group of the people are given training by the expert’s subject matter, in
the big rooms/halls/
• Video training: there are some training in the industry, which are given online before
coming to the hazardous places in the chemical plants,
Training classes: the special training classes and workshops are done to give the
introduction and training tasks to the employees, like in the paint industry.
• Training books and materials: The special training materials, lectures, and books are
given to the employees of the paint industry and other industries to train new and old
employees
Feedback system development: The feedback system helps to keep the process in the control limits
External monitoring by third party: There are some industries, which uses the system for the third
party like supply chain management outsourcing or the external audits
Safety process: yes! Safety is the back bone of the process; The safety system and experts are used to
control the incident before it happens. The safety control devices are also used in this manner, like
extinguishers and sprinkling system.
Procedures for Standard Work
Standard works
• Instructions
• Takt time
• Sops
• Control charts
• Visual signs
• Do work according to Sequence/SIPOC
• Quality controlling
• Assign roles & responsibilities to people
• Use lean tools
• Training system
• Monitoring & supervision
• Motivation
• Leadership
• Get high efficiency
Documentations: All the process in the industry is done on documentation, The inventory system to the
production, finance and management, all the systems are done on the documentations.
• File and computer files
• Software data
Training Plans
• On job training: This process is mainly adopted in the paint industry, where the new
employee or old employee is given the training during the job. This is very good
method to give the training with practical work.
• Off job training: there certain sessions takes place in which the training is given in
the classes
• Seminars: The group of the people are given training by the expert’s subject matter,
in the big rooms/halls/
• Video training: there are some training in the industry , which are given online
before coming to the hazardous places in the chemical plants,
Training classes: the special training classes and work shops are doness to give the
introduction and training tasks to the employees, like in the paint industry.
• Training books and materials: The special training materials, lectures, and books
are given to the employees of the paint industry and other industries to train new and
old employees
Process Capability - Post Implementation
Control charts
Histograms
Trend analysis
Training Plans
On job training: This process is mainly adopted in the paint industry, where the new employee or old
employee is given the training during the job. This is very good method to give the training with practical
work.
Off job training: there certain sessions takes place in which the training is given in the classes
Seminars: The group of the people are given training by the expert’s subject matter, in the big
rooms/halls/
Video training: there are some training in the industry , which are given online before coming to the
hazardous places in the chemical plants,
Training classes: the special training classes and work shops are doness to give the introduction and
training tasks to the employees, like in the paint industry.
Training books and materials: The special training materials, lectures, and books are given to the
employees of the paint industry and other industries to train new and old employees
