premium transport

8/10/2019 Premium Transport

1/40


2/40

Tollgate Review

D M A I C

Project Title: Premium Reduction

Contract

Department Customer (internal/external):

Duration internal: PC&L

Sponsor:

CTQ addressed:Eric Crump PC&L Manager - Project Leader

Marne Cario PC&L General Supervisor

Business Driver(s) Impacted:

Project Scope:

Tools Used

Define

actual

Measure

actual

Analyze

actual

Improve

actual

Control

actual Control and Response Plan

Total Months: 6August 2004 - February 2005

Contract / SIPOC / Graphs

Preliminary Problem Statement:

Aug

Rachel Heidenreich

PC&L

Premium / IPM (Internal & External)

Premium Cost Reduction / IPM Internal And

External Delivery Improvement

Donnell Conner

Champion: Marybeth Cunningham

Team Members

Tool Engineer

MFG Superv isor

Role

Dec

Jim Altier

Tom Catheline

William Katko

John Salerno

Nov

Quality Engineer Green Belt Candidate

Green Belt Re-Certification

Function

Manufacturing Support

Black Belt Candidate

Process Mapping, Cause and Effect Diagram,

Data collection Plan, MSA

DPMO/Capability, Hypothesis Testing/Root

Cause Analysis

Solution generate, Pilot on Department 1108,

Moods Median Test, Test for Equal Variance

Mar Apr

Ken Dillon PC&L Scheduler - Project Leader

Jan Feb

Chris Kushmaul Master Black Belt

Master Black Belt

Shipping Supervisor

Sep Oct

In Scope - Reduction of all Premium from Pt 11

Green Belt Candidate

Green Belt Re-Certification

Project Coach



Text: Plant has been experiencing high premium transportation over the past 2 years. 2003 premium was over $220,000 and 2004

premium is over $250,000 thru July. In addition to high premium, Plant 11 has experienced internal and external delivery issues to

several customers. Delivery Performance has created several concerns from the DCS Business Line because of the impact to their final

customers.

The goal of this project is to reduce Premium by 40% and reduce IPM by 45%


3/40

Tollgate Review

D M A I C

$183

,411

$19,

571

$11,

181

$5,58

4

$1,224

$774

$200

$108

$124$64

$0

$20,000

$40,000

$60,000

$80,000

$100,000

$120,000

$140,000

$160,000

$180,000

$200,000

BehindSchedule

InternalQuality

SupplierQuality

Trans /Customs

DeliverMiss

Late Entry Mislabeled Cust. Req /Inv. Adj

Req /Inventory

Adj.

Part Cert.Delay

Plant Premium 200x Detail

Data was obtained from the Premium Web Site


4/40

Tollgate Review

D M A I CPlant Premium 200x Detail

$220

,019

$20,

492

$7,3

38

$1,850

$1,612

$1,11

0

$65

9

$30

0

$0

$50,000

$100,000

$150,000

$200,000

$250,000

Behind

Schedule

Trans /

Customs

Data

Processing

Engineering Internal

Quality

Deliver Miss Req /

Inventory

Adj.

Tool

Capacity



5/40

Tollgate Review

D M A I CPlant 200x Internal IPM


27 0 0 23

9

2,04

7 2,50

7

2,16

9

4,89

4

7,65

5

261

3,83

4

2,89

2

9,25

2

0

1,000

2,000

3,000

4,000

5,000

6,000

7,000

8,000

9,000

10,000

Jan Feb March April May June July Aug Sept Oct Nov Dec YTD


6/40

Tollgate Review

D M A I CPlant 200x Internal IPM


3,22

5

2,20

6

508

799

2,08

9

1,97

6

243

1,596

0

500

1,000

1,500

2,000

2,500

3,000

3,500

Jan Feb March April May June July YTD


7/40

Tollgate Review

D M A I CSIPOC

Process Name: Plant 11 Terminal Manufacturing Process

Process Owner: Plant 11 Premium Reduction Team

Suppliers Inputs Process Outputs

(Providers of the

required resources)

(Resources required by

the process)

(Deliverables from

the process)

Customer Forecast Requirements

Pulls

Orders Parts Shipped on Time INTERNAL

Mexico

PC&L Production Schedules Mississippi

Quality PPAP Good Quality Parts

Tool Release

Press ReleasePart Inspection (PPC)

Manufacturing Production Right Quantities

Tool Room Tools

Tool & Die Makers Set - UP

EXTERNAL

Correctly Labeled Lear

Tool Engineer Support Yazaki PS&G

Maintenance Support Condumex

Change-over

Terminal Store Matrial Handling

Shipping

Develop Store Goal

Suppliers Raw Material

Customers

(Stakeholders who place the requirements on

the outputs)

Customer

Requirements

Forecast

Pulls (Internal)

Orders (External)

Scheduling

Manufacuturing

SHIP

from

OHIO

TERMINALS


8/40

Tollgate Review

D M A I C

Plant Premium Reduction &

Delivery Improvement

Measure

Date: 01 / 06 / 0x


9/40

Tollgate Review

D M A I CCause & Effect Diagram

(Goal Changes)

(Note comment from Red Tags?)

(1 - Group with FTQ?) Should add up to

84

(1 - Group w / Un-forcasted orders / pulls?)

PC&L Manufacturing Information Systems

Customer/Supplier Eng/Tool Room/Maint. Quality

Why do We havemissed/late

shipments?

(x) Lack - Order Fillers

1

(x) Critical Parts List

(x) Terminal StorePicks

(x) Partial Reels

(x) Lack - Raw

Material

(x) Mtl Movement

Delays

(x) LaborAllocation/Job

(x) OperatorTraining

(x) Care Insp.Coverage

(x) Line Insp.Coverage

(x) Absenteeism

(x) Uptime

(x) Lack - RealTime Info

(x) ShippingPatterns 1

3

2

(x) Scrap

(x) PressAvai labili ty 4

2

1

1

7

(x) InventoryVisibility

(x) Real Time Data

(x) Label

4

1

(x) GoalChanges

Defective

Raw

(x) Pull Variations

(x) Increased Pulls

(x) UnforseenOrders/Pulls

5

2

6

ChangeoverTime 6

Issues Running 2Precious Metal

Labor

Resourcing/Job Ass

6

Setup Times

3 ToolAvailabili ty

6 Tool Capability

Unplanned 3Mtce. Downtime

Make vs Buy

Low Vol. & 4Obsolete Parts

Spare ToolingParts 4

Spare Equip.

Parts

Mtce. Response

Time 6

(x) PPAP

(x) Red Tags

(x) FTQ

3

1


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Tollgate Review

D M A I CData Collection Plan

Time Period (Y) (X1) (X2) (X3) (X4) (X5)

Joe Bonneau John Salerno Joe Bonneau Ken Dillion Ken Dillion John Salerno

Name of Factor: Operator (1) (2) Trial Part Number Time to fill back

order

Uptime Set up / Change

Over

Tool

Availability

Press Availability Spare Tooling Part

Availability

Operational Definition

The uptime of the

press while the back

order part number is

in the machine

Time to convert

good part to good

part

Sitting on

ready rack

Is an acceptable

press available to

the run part?

The time it takes to

get spare toolign

when parts are not

available

Type of Data: Continuous Continuous Discrete Dicrete Continuous

Specific to:

P/N's

Measure

Data Collection Plan


11/40

Tollgate Review

D M A I C

Time Period (Y) (X6) (X7) (X8) (X9) (X10)Joe Bonneau Donnell Conner John Salerno Marne Cario Marne Cario Bill Katko

Name of Factor:Operator (1)

(2)Trial Part Number

Time to fill back

order

Maintenance

Response Time

Tool & Die Response

Time

Unforeseen

Orders / Pulls

Low Volume Red Tag

Operational Definition

Time from

when a call is

placed to the

time the work

is complete

The difference in time

between when a tool

has failed & marked on

the board & when the

machine is running

Difference

between the

forecast & the

actual pull

Is this part

number low

Volume?

Is this part red

tag or care?

Type of Data: Continuous Continuous Continuous Discrete Discrete

Specific to:Rounded to the hour

checked

Build area

1118

First time?

Quality?

P/N's

Measure




12/40

Tollgate Review

D M A I CGage R & R Study

Repeatability Within Appraisers

Appraiser #Inspected

# Matched % Percent 95.0% CT

21 30 30 100 (90.5 , 100)

2 30 29 96.7 (82.8 , 99.9)

# Inspected # Matched % Percent 95.0% CT

30 29 96.7 (82.8 , 99.9)

Appraiser agrees with him / herself trials

Reproducibility Between Appraisers

All appraisers assessments agree with each other


13/40

Tollgate Review

D M A I C

Plant Premium Reduction &

Delivery Improvement

Analyze

Date: 03 / 24 / xx


14/40

Tollgate Review

D M A I C

1 4 7 10 13

95% Confidence Interval for Mu

1.5 2.5 3.5

95% Confidence Interval for Median

Variable: (Y)

A-Squared:P-Value:

MeanStDevVarianceSkewness

KurtosisN

Minimum1st QuartileMedian3rd QuartileMaximum

2.6522

2.5589

1.6000

5.2690.000

3.186092.890368.354191.32074

1.59636115

0.30001.00002.30005.4000

14.0000

3.7200

3.3212

2.7000

Anderson-Darl ing Normality Test

95% Confidence Interval for Mu

95% Confidence Interval for Sigma

95% Confidence Interval for Median

Time a Part is on Backorder (days)USL = 2 Days

DPMO = 1.4

sigma process

Descriptive Statistics

The median t im e for parts on backo rder is 2.3 days. With a target of 2 days

our process defect rate is 53%


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Tollgate Review

D M A I CDescriptive Statistics

1106010

14

12

10

8

6

4

2

0

Observation

(Y)

0.5296

0.4704

3.0000

76.333376.0000

0.5370

0.4630

10.0000

58.495758.0000

Approx P-Value for Oscillation:

Approx P-Value for Trends:

Longest run up or down:

Expected number of runs:Number of runs up or down:

Approx P-Value for Mixtures:

Approx P-Value for Clustering:

Longest run about median:

Expected number of runs:Number of runs about median:

Run Chart for (Y)

Our proc ess is stable with no clus ter ing, mixtures, t rends , and osc i l lat ions


16/40

Tollgate Review

D M A I CIdentify variation Sources

Factor Name Data Type Analysis Tools Statistically Significant

X1 Press Uptime ContinuousSimple Linear RegressionMood's Median Test

Test for Equal Variances

No

X2 Set Up / Change Over ContinuousSimple Linear RegressionMood's Median TestTest for Equal Variances

No

X3 Tool Availability DiscreteMood's Median TestTest for Equal Variances

No

X4 Press Availability DiscreteMood's Median TestTest for Equal Variances

No

X5 Spare Tooling PartAvailability

Discrete Mood's Median TestTest for Equal Variances

No

X6Mantenance ResponseTime

ContinuousSimple Linear RegressionMood's Median TestTest for Equal Variances

Yes - Difference in Center

X7Tool & Die ResponseTime

ContinuousSimple Linear RegressionMood's Median TestTest for Equal Variances

Yes - Difference in Center andvariation

X8 Orders vs. Pulls DiscreteMood's Median TestTest for Equal Variances

No

X9 Low Volume DiscreteMood's Median TestTest for Equal Variances

No

X10 Red Tag or Care DiscreteMood's Median TestTest for Equal Variances

No

X11 Start-Stop Part DiscreteMood's Median TestTest for Equal Variances

No


17/40

Tollgate Review


X1

Y1

9080706050403020100

30

25

20

15

10

5

0

S 3.69418

R-Sq 3.7%

R-Sq(adj) 2.9%

Fitted Line PlotY1 = 4.632 - 0.04227 X1

Data analysis sh ows that machine upt im e and t im e to f i l l a backord er do not

have a strong c orrelat ion no t stat is t ical root c ause

Regression Analysis: Y1 versus X1 (Uptime)

The regression equation is

Y1 = 4.632 - 0.04227 X1

S = 3.69418 R-Sq = 3.7% R-Sq(adj) = 2.9%

Analysis of Variance

Source DF SS MS F P

Regression 1 62.52 62.5237 4.58 0.034

Error 120 1637.63 13.6470

Total 121 1700.16

X1 - Uptime


18/40


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Tollgate Review

D M A I C

X3

Y1

YN

30

25

20

15

10

5

0

Boxplot of Y1 vs X3

Identify variation Sources

X3 Tool Availability

No dif ference in either the center (median) or sp read (variat ion) between too l

Avai lable yes vs. no no t stat is t ical root cause

Mood Median Test: Y1 versus X3

Mood median test for Y1

Chi-Square = 0.00 DF = 1 P = 0.948

Individual 95.0% CIs

X3 N Median Q3-Q1 ---+---------+---------+---------+---

N 7 7 2.35 5.63 (--------*--------------------------)

Y 55 53 2.30 4.30 (---*--)

---+---------+---------+---------+---

1.5 3.0 4.5 6.0

Overall median = 2.30

Test for Equal Variances: Y1 versus X3

95% Bonferroni confidence intervals for standard deviations

X3 N Lower StDev Upper

N 14 2.12450 3.06088 5.31933

Y 108 3.32853 3.84031 4.52931

F-Test (normal distribution)

Test statistic = 0.64, p-value = 0.361

Levene's Test (any continuous distribution)



20/40

Tollgate Review

D M A I C

X4

Y1

YN

30

25

20

15

10

5

0

Boxplot of Y1 vs X4


X4 Press Availability

The p values are greater than .05; we accept th e null hypo thesis ~ there is

no d if ference in backo rder t ime when a press is avai lable yes vs. no



Chi-Square = 1.11 DF = 1 P = 0.293


X4 N Median Q3-Q1 ---+---------+---------+---------+---

N 22 16 1.65 5.00 (---------*-------------------)

Y 40 44 2.40 4.40 (-----------*------------)

---+---------+---------+---------+---

1.20 1.80 2.40 3.00


A 95.0% CI for median(N) - median(Y): (-1.70,0.60)




N 38 4.11245 5.18848 6.98004

Y 84 2.47510 2.90730 3.51331

F-Test (normal distribution)Test statistic = 3.18, p-value = 0.000




21/40

Tollgate Review

D M A I C

X5

Y1

YesNo

14

12

10

8

6

4

2

0

Boxplot of Y1 vs X5


X5 Spare Tooling PartAvailability

Altho ugh the medians appear di f ferent , there is n ot enoug h d ata to stat ist ica l ly

con clud e there is a dif ference there were only six samples w hen spare

tool ing was no t avai lab le

Mood Median Test: Y1 versus X5Mood median test for Y1

Chi-Square = 0.70 DF = 1 P = 0.401


X5 N Median Q3-Q1 -------+---------+---------+---------

N 2 4 4.30 5.83 (-------------*--------------------)

Y 54 52 2.30 4.40 (--*-)

-------+---------+---------+---------

2.5 5.0 7.5


A 95.0% CI for median(N) - median(Y): (-2.00,9.70)




N 6 2.34663 4.00221 11.4501

Y 106 2.46978 2.85313 3.3707

F-Test (normal distribution)Test statistic = 1.97, p-value = 0.179




22/40

Tollgate Review

D M A I C

X6

>4

95% Bonferroni Confidence Intervals for StDevs

Yes

No

5.04.54.03.53.02.52.0

X6

>4

Y1

Yes

No

14121086420

F-Test

0.124

Test Statistic 0.67

P -Valu e 0.197

Levene's Test

Test Statistic 2.41

P-Value

Test for Equal Variances for Y1

X6 > 4

Y1

YesNo

14

12

10

8

6

4

2

0

Boxplot of Y1 vs X6 > 4


X6 Maintenance ResponseTime

Stat ist ical Root Cause w ith a p-value of .004 we reject th e nul l hy poth esis;

there is a dif ference in times. When the maintenance cal l takes over 4 hours

then the backo rder t ime goes up sig ni f icant ly! !

Mood Median Test: Y1 versus X6 > 4


Chi-Square = 8.35 DF = 1 P = 0.004


X6 > 4 N Median Q3-Q1 -----+---------+---------+---------+-

No 53 40 1.70 3.00 (---*--)

Yes 5 17 5.70 4.73 (---------------*-----)

-----+---------+---------+---------+-

2.0 4.0 6.0 8.0



23/40

Tollgate Review

D M A I C

X7

>4


Yes

No

4.03.53.02.52.0

X7

>4

Y1

Yes

No

14121086420

F-Test

0.059

Test Statistic 1.02

P -Valu e 0.897

Levene's Test

Test Statistic 3.63

P-Value

Test for Equal Variances for Y 1


X7 Tool & Die Repair Time

Stat ist ical Root Cause w ith a p-value of .001 we reject th e nul l hy poth esis;

there is a dif ference in t imes. When the maintenance call takes over 4 hours

then the backord er t ime goes up

X7 > 4

Y1

YesNo

14

12

10

8

6

4

2

0

Boxplot of Y1 vs X7 > 4

Mood Median Test: Y1 versus X7 > 4

Mood median test for Y1Chi-Square = 11.72 DF = 1 P = 0.001


X7 > 4 N Median Q3-Q1 -----+---------+---------+---------+-

No 22 6 1.00 1.53 (----*---)

Yes 36 51 2.70 5.00 (---*--------)

-----+---------+---------+---------+-

1.0 2.0 3.0 4.0



24/40

Tollgate Review

D M A I C

X8

Y1

YesNo

14

12

10

8

6

4

2

0

Boxplot of Y1 vs X8


X8 Orders vs. PullsMood Median Test: Y1 versus X8

Mood median test for Y1Chi-Square = 0.01 DF = 1 P = 0.928


X8 N Median Q3-Q1 ---+---------+---------+---------+---

No 28 28 2.35 3.55 (----------*--)

Yes 30 29 2.30 4.40 (---------------*-----------------)

---+---------+---------+---------+---

1.40 2.10 2.80 3.50


X8


Yes

No

4.03.53.02.52.0

X8

Y1

Yes

No

14121086420

F-Test

0.273

Test Statistic 0.76

P -Valu e 0.299

Leven e's Test

Test Statistic 1.21

P-Value

Test for Equal Variances for Y1

No dif ference in either the center (median) or sp read (variat ion) when we ask

If the pu l l was greater than the order, yes vs . no no t stat is t ical root cause


25/40

Tollgate Review

D M A I C

(X9)

(Y)

YN

14

12

10

8

6

4

2

0

Boxplot of (Y) vs (X9)


X9Low Volume



Chi-Square = 1.01 DF = 1 P = 0.315


X9 N Median Q3-Q1 -------+---------+---------+---------

N 53 53 2.35 4.10 (---*-)

Y 9 5 1.85 6.98 (-----*--------------------------)

-------+---------+---------+---------

2.0 4.0 6.0


(X9)


Y

N

98765432

(X9)

(Y)

Y

N

14121086420

F-Test

0.282

Test Statistic 0.35

P -Valu e 0.007

Levene's Test

Test Statistic 1.17

P-Value

Test for Equal Variances for (Y)


If the part is low volume, yes vs. no no t stat is t ical root cause


26/40

Tollgate Review


X10 Red Tag or Care

X10

Y1

YesNo

14

12

10

8

6

4

2

0

Boxplot of Y1 vs X10



Chi-Square = 1.31 DF = 1 P = 0.253


X10 N Median Q3-Q1 ------+---------+---------+---------+

No 21 15 1.85 4.30 (-----------*-------------)

Yes 37 42 2.40 4.40 (----------*------------)

------+---------+---------+---------+

1.40 2.10 2.80 3.50


X10


Yes

No

4.254.003.753.503.253.002.752.50

X10

Y1

Yes

No

14121086420

F-Test

0.941

Test Statistic 1.17

P -V alu e 0.567

Leven e's Test

Test Statistic 0.01

P-Value

Test for Equal Variances for Y 1


If the material had any pieces in redtag, yes vs . no no t stat is t ical root cause


27/40

Tollgate Review


X11Start/Stop Part

X12

(Y)

YesNo

14

12

10

8

6

4

2

0

Boxplot of (Y) vs X12

Mood Median Test: (Y) versus X12

Mood median test for (Y)Chi-Square = 3.28 DF = 1 P = 0.070


X12 N Median Q3-Q1 ---+---------+---------+---------+---

No 29 19 1.50 4.60 (-------*--------------------------)

Yes 29 38 2.40 4.40 (-----------*---------)

---+---------+---------+---------+---

1.20 1.80 2.40 3.00


X12


Yes

No

4.03.53.02.52.0

X12

(Y)

Yes

No

14121086420

F-Test

0.476

Test Statistic 1.49

P -Valu e 0.131

Levene's Test

Test Statistic 0.51

P-Value

Test for Equal Variances for (Y)


If this PN was a start/stop part, yes vs. no no t stat is t ical root cause


28/40

Tollgate Review

D M A I CAnalyze Take - Aways

- Maintenance Response Time is a significant contributor toTime to Fill Back Order (Y)

- Tool & Die repair time is a significant contributor to Time toFill Back Order (Y)

- Both Maintenance Response Time and Tool & Die Repair

Time impact Uptime but Uptime alone is not a significantfactor

- Other potential causes (Xs) did not show significant impactto Time to Fill Back Order

- This statistical data indicates that in order to reduce the Timeto fill a Back Order, which potentially leads to premium, wemust reduce the Maintenance Response Time and the Tool& Die Repair Time


29/40

Tollgate Review

D M A I CNext Steps

- Continue in the Improve Phase

- Develop solutions to improve Maintenance Response Timeand Tool & Die Repair Time

- Collect Data from the Recommended improvement plan

- Evaluate if corrective actions reduce or eliminate the impactof Maintenance Response Time and Tool & Die Repair Timeon the Time to Fill a back Order / Premium


30/40

Tollgate Review

D M A I C

Plant Premium Reduction

& Delivery Improvement

Improve / ControlDate: 05 / 05 / xx


31/40

Tollgate Review

D M A I CDevelop Solut ions

- Tool & Die Repair Time Solutions

- Dedicated Tool & Die support on all Shifts- Use the Andon System to improve call priorities

- Die Maker inspects and releases parts in place of a traditional release person

- Document all Die changes in the log book

- Dedicated tool makers for different die families

- Maintenance Response Time Solutions

- Dedicated Machine and Maintenance Repair support and on all shifts

- Use the Andon System to improve call priorities

- PC&L notifies maintenance when a part goes on back order- Maintenance Supervisor copied on all critical parts


32/40

Tollgate Review

D M A I CTest Solutions - Pilot

Subscripts


1108

1119

2.52.42.32.22.12.01.91.8

Subscripts

Y

1108

1119

2520151050

F-Test

0.000

Test Statistic 1.38P -Value 0.001

Levene's Test

Test Statistic 16.49

P-Value

Test for Equal Variances for Y

Results for: 1108 vs. 1119

Mood Median Test: YMood median test for Y

Chi-Square = 60.60 DF = 1 P = 0.000


Subscripts N Median Q3-Q1 +---------+---------+---------+------

1119 62 150 2.40 2.68 (-------*-----)

1108 789 574 1.40 1.80 (-------*

+---------+---------+---------+------

1.00 1.50 2.00 2.50


A 95.0% CI for median(1119) - median(1108): (0.60,1.30)

Test for Equal Variances: Y

95% Bonferroni confidence intervals

Subscripts N Lower StDev Upper

1119 212 2.01797 2.23877 2.51152

1108 1363 1.82901 1.90766 1.99312

F-Test (normal distribution)




The p values are less than .05; we reject the null h ypoth esis ~ there is a

dif ference in backord er. The solut io ns have impacted both var iation and median


33/40

Tollgate Review

D M A I CNew Capability Analysis

Total

1119

1108

Characteristic

1.920

1.370

2.014

ZBench

1.500

1.500

1.500

ZShift

337143

551887

303742

PPM

0.337143

0.551887

0.303742

DPO

0.552

0.304

DPU

1575

212

1363

TotOpps

1

1

Opps

212

1363

Units

531

117

414

Defs

Capability Analysis

Applying th e goal of less than 2 days o n backord er the solu t ions implemented

impro vement ou r process from 1.4 sigma to a 2 sigma process.


34/40

Tollgate Review

D M A I CTimeline for Full Solution Implementation

- Department 11xx was the first module installed.

- Implementation of the remaining modules that will utilizethese solutions are as follows:

- Department 11xx will be completely installed by 5/15/xx



- Department 11xx (Low Volume) will be completely installed by 10/xx

- Department 11xx will be replaced by 11xx (8/1/xx)

- Department 11xx will be replaced by 11xx (6/1/xx)


35/40

Tollgate Review

D M A I CFinancial Impact

- JanuaryApril of 200x compared to JanuaryApril 200x indicates areduction in premium of 16%, 80%, 84.5% and 31.4% respectively.

- This equates to a 61.9 % reduction in premium over the same four month period.

- Over the last two months departments without the improvements haveaccounted for significantly more premium than department 110x.

- Dept 110x Non-Improved Depts

- March 18.0 % 52.0 % (1119)

- April 27.8 % 58.9 % (1116)

- Our implemented solutions improved our process by 30 %- From 1.4 Sigma to a 2.0 Sigma

- Our implemented solutions reduced our median time to fill a back orderby 41.6 %

- From a median of 2.4 to a median of 1.4

- Based on these improvements we conclude that the plant 11 premiumwill be reduced by approximately 34.0 %

- Based on 200x premium of $308,940, the financial impact will be areduction in premium of $105,040.00 per year.


36/40

Tollgate Review

D M A I CContro l Plan

- Plant xx team should monitor Maintenance Response Timeand tool & Die Repair time.

- This should be monitored on a monthly basis.

- If Maintenance Response Time or Tool & Die Repair Time isgreater than 4 hours, plant should investigate root cause

- Need to determine responsible person (s) to monitor theseissues

- System generated reports for Maintenance Response Time

and Tool & Die Repair Time will support in this effort


37/40


38/40

Tollgate Review

D M A I C

Back-up


39/40

Tollgate Review

D M A I C

$2,580

$2,382

$6,8

37

$2,694

$11,

420

$6,8

37

$14,

814

$3,602

$1,576

$678

$

512

$1,552

$0

$2,000

$4,000

$6,000

$8,000

$10,000

$12,000

$14,000

$16,000

Janu

ary

Febu

rary

Mar

chAp

rilM

ayJu

ne July

Augu

st

Sept

embe

r

Octo

ber

Nove

mbe

r

Dece

mbe

r

Plant xx- Dept. xxxx Premium in 200x


D M A I C


40/40

Tollgate Review

D M A I C

$2,168

$456

$1,056

$1,847

$0

$500

$1,000

$1,500

$2,000

$2,500

January Feburary March April

Plant xx- Dept. xxxx Premium in 200x


premium transport

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