Sure, here's a more detailed example of how you can approach the Improve phase of your Six Sigma
project using Design of Experiments (DOE) and brainstorming:
### 1. Brainstorming Session:
- **Objective:** Reduce defects related to thickness, shrinkage, grade deviation, and size variation in
the tannery process.
- **Team:** Gather a team including process experts, operators, quality control personnel, and
relevant stakeholders.
- **Techniques:** Use mind mapping or the nominal group technique to stimulate idea generation.
### 2. Prioritize Ideas:
- After brainstorming, prioritize the ideas based on:
- Potential impact
- Feasibility
- Cost
### 3. Develop Solution Concepts:
- **Idea 1:** Improve Thickness Control
- Solution Concept: Implement tighter control measures on the thickness of tanned leather.
- **Idea 2:** Reduce Shrinkage
- Solution Concept: Modify the tanning process to reduce the occurrence of shrinkage.
- **Idea 3:** Grade Deviation Reduction
- Solution Concept: Implement a stricter sorting process to minimize grade deviation.
- **Idea 4:** Size Variation Reduction
- Solution Concept: Implement a more accurate cutting process to reduce size variation.
### 4. Design of Experiments (DOE):
- **Variables to Test:**
- Thickness control settings
- Tanning process parameters affecting shrinkage
- Sorting process parameters affecting grade deviation
- Cutting process parameters affecting size variation
- **Levels to Test:**
- For each variable, identify the range of levels to test.
- **Experimental Design:**
- Use a factorial design to test multiple variables simultaneously.
- Randomize the order of experiments to minimize bias.
- Replicate experiments to ensure reliability.
### 5. Implementation Plan:
- **Based on the results of the DOE, develop an implementation plan for the most effective
solutions.**
- **Define responsibilities, timelines, and metrics for monitoring the effectiveness of the implemented
solutions.**
- **Plan for continuous improvement and ongoing monitoring of the tannery process.**
This structured approach should help you effectively identify, prioritize, and implement solutions to
reduce defects in the tannery process. Does this help clarify the process for you?
Of course! Let me provide more details on the brainstorming session:
### 1. Brainstorming Session:
**Objective:**
Reduce defects related to thickness, shrinkage, grade deviation, and size variation in the tannery
process.
**Team:**
Gather a team including process experts, operators, quality control personnel, and relevant
stakeholders.
**Techniques for Idea Generation:**
1. **Mind Mapping:**
- Start with a central idea (e.g., "Defect Reduction in Tannery Process").
- Branch out to related aspects (thickness, shrinkage, grade deviation, size variation).
- Each aspect can further branch out to potential causes and solutions.
2. **Nominal Group Technique:**
- Each team member independently generates ideas.
- Ideas are then presented to the group, and similar ideas are grouped together.
- Group discusses and refines the ideas.
**Example:**
- Central Idea: Defect Reduction in Tannery Process
- **Branches:**
- Thickness Control
- Tighter control measures
- Advanced measurement techniques
- Shrinkage Reduction
- Tanning process modifications
- Temperature and humidity control
- Grade Deviation Reduction
- Sorting process improvements
- Quality control checkpoints
- Size Variation Reduction
- Cutting process enhancements
- Automated size measurement tools
**Outcome:**
A comprehensive list of potential solutions to address the identified defects, ready for prioritization and
further development.
Would you like more information on any specific aspect?
Absolutely, incorporating factors such as skin quality, pH levels, thickness, and elongation percentage
into the brainstorming session is a great idea. Let's modify the example brainstorming ideas accordingly:
### Example Brainstorming Ideas:
- **Central Idea:** Defect Reduction in Tannery Process
- **Branches:**
1. **Thickness Control:**
- Tighter control measures
- Advanced measurement techniques
- Monitoring and adjusting pH levels during tanning
2. **Shrinkage Reduction:**
- Tanning process modifications
- Temperature and humidity control
- Adjusting pH levels to optimize tanning process
3. **Grade Deviation Reduction:**
- Sorting process improvements
- Quality control checkpoints
- Monitoring skin quality before and after tanning
4. **Size Variation Reduction:**
- Cutting process enhancements
- Automated size measurement tools
- Monitoring elongation percentage to ensure uniformity
**Outcome:**
By including factors such as skin quality, pH levels, thickness, and elongation percentage, we have
expanded our brainstorming ideas to cover a broader range of potential causes and solutions for defect
reduction in the tannery process.
Does this modified brainstorming session align more closely with your requirements?
Absolutely, let's delve deeper into the brainstorming ideas and how factors like skin quality, pH levels,
thickness, and elongation percentage can be incorporated:
### Example Brainstorming Ideas:
- **Central Idea:** Defect Reduction in Tannery Process
- **Branches:**
1. **Thickness Control:**
- Implement tighter control measures on thickness.
- Use advanced measurement techniques such as digital thickness gauges.
- Monitor and control pH levels during the tanning process to ensure consistent thickness.
- Optimize tanning process parameters to achieve desired thickness.
2. **Shrinkage Reduction:**
- Modify the tanning process to reduce the occurrence of shrinkage.
- Control temperature and humidity levels during the tanning process.
- Adjust pH levels to optimize the tanning process and minimize shrinkage.
- Monitor and control skin quality to minimize variations that may lead to shrinkage.
3. **Grade Deviation Reduction:**
- Implement stricter sorting processes based on skin quality, thickness, and elongation percentage.
- Introduce quality control checkpoints at various stages of the tanning process.
- Monitor and control pH levels to ensure consistent grade quality.
- Implement measures to improve skin quality before and during the tanning process.
4. **Size Variation Reduction:**
- Enhance cutting processes to ensure uniform size and shape.
- Implement automated size measurement tools to reduce human error.
- Monitor and control elongation percentage to ensure uniformity in size.
- Optimize cutting parameters based on skin quality, thickness, and elongation percentage.
**Outcome:**
By incorporating factors such as skin quality, pH levels, thickness, and elongation percentage into the
brainstorming session, we have identified a more comprehensive list of potential causes and solutions
for defect reduction in the tannery process. This will help in developing a more effective improvement
plan during the Improve phase of the DMAIC methodology.
Does this provide the clarity you were looking for?
