B.
Measure Phase
This phase presents the detailed process mapping, operational definition, data collection chart, evaluation of the existing system, assessment of the current level of process performance etc.
Process Mapping
The process map of the SAW Boom machine welding process (fig. 5) is prepared by visually studying the process and then mapping various sub-activities in it. This mapping helped to visualize and separate value-added activities from NVA activities and to isolate the hidden waste streams.
Operational Definition:-
Yield of SAW Boom machine process is defined as the ratio of net operating hrs to gross available hrs..
Type of Data
The type of data is continuous (variable).
Assessing current level of process performance (process sigma level) Net operating hrs. (on job)Yield of A101 SAW BoomGross available hrs.machine welding process =2542411261.8%==
From process-sigma conversion table, current process sigma level is 1.8 for process yield of 61.8%.
C.
Analyze phase
This phase describes the potential causes identified which have the maximum impact on the low process yield, cause-and-effect diagram, Pareto analysis of the causes, the Why Why analysis, FMEA analysis which leaded to identify the vital few factors in order to identify the root causes of the defects / problems and helped to examine the processes that affect the CTQs and decide which X’s are the vital few that must be controlled to result in the desired improvement in the Y’s, this leaded to generate ideas for improvement.