Six Sigma Control Phase April 2017 5th Submission

Control Phase 16/04/17: Phase Learning's and Tools Utilised.

Control Phase:

Phase Learnings:

The Control Phase of the project is the requires monitoring, standardizing and completion of FMEA's post Improve Phase.

The key learning for this phase s the importance of standardizing the improvements and ensuring the effectivity of these improvements.

All programs with cross drilled holes have been updated and the machining parameters have will be recorded in a Process Characterization Report which will form part of the design Dossier for the parts.

It is also important to reflect on the project learnings too by form of a Lessons Learned to allow for the pitfalls and benefits to be highlighted for subsequent projects.

Within the time frame assigned for this project a simple production tracker has been introduced to assess the micro-drill process performance on all applicable batches built on the Swiss Turn Machines.

Tools Utilized:

FMEA:

The FMEA for the Process was revisited to assess the impact of the studies and the changes made during the Improve Phase. This to ensured that the required actions were completed and the impact was assesed. The final Column set in the FMEA quantifies the changes made and the new RPN for the failure mode. All identified modes have been addressed and the RPN for each mode has been reduced.

Fig1: Completed FMEA

Process Monitoring:

The current production builds are being monitored and tracked for Micro Drill Failures. 

To date after 380 parts no defects have been recorded for Micro Drill Defects.

Ideally the Control Phase of the project should allow more time to verify the results of the project. 

However the trend to date over build completed is positive with 100% yield across all batches.

Fig 2: Process Yield Metrics Pre and Post Process Improvements

Lessons Learned:

The Final tool adopted for the projects was a Lessons Learned. This was completed as part of a team review of teh project and the results of the review were documented and will be recorded within the final report. 

The Key learnings highlighted for the project were the Time lines associated with the project. At times the completion of the trials was impeded by production tasks.

The otehr key learning for the team was the benefit of the drill length setup piece. This methodology will be implemented across all the other tools on the machine to aid setup and to reduce First part yield at setup.