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1. Six Sigma in Action:
Demonstrating Customer Value
Master Black Belt: Steven Bonacorsi

2. Six Sigma in Action:
Data Conversion Cycle Time
Customer Profile – GE Aircraft Engines, Evandale, OH
Business Problem & Impact Process Capability – Before
The data conversion process within the install process can take up to 5 P ro c e s s C ap ab ility A nalys is fo r T o tal T im e
or 6 hours to complete, requiring extra resources for refresh and installs.
USL
Proc es s Data
Measure & Analyze USL
Target
120.000
*
ST
LT
LSL *
Data Collection: Cycle times were measured (average was 90 Mean
Sample N
90.740
30
minutes), then segmented by time of day, type and size of files, etc. to StDev (ST) 64.1700
StDev (LT) 75.7250
identify and isolate root causes.
Root Causes: File sizes, network traffic, and obsolete compression Cp
Potential (ST) Capability
*
CPU 0.15
processes were determined to be the major causes of process defects CPL *
Cpk 0.15
Improve & Control Cpm *
-100 0 100 200 300 400
Network issues were completely eliminated by utilizing direct PC Ov erall (LT) Capability Obs erv ed Perf ormanc e Ex pec ted ST Perf ormanc e Ex pec ted LT Perf ormanc e
Pp * PPM < LSL * PPM < LSL * PPM < LSL *
connection to a mobile laptop and network crossover cables during PPU 0.13 PPM > USL Process Capability – After
266666.67 PPM > USL 0.00 PPM > USL 0.00
PPL * PPM Total 266666.67 PPM Total 0.00 PPM Total 0.00
setup. The ITS project leader developed the QuickBack 32 application to Ppk 0.13 USL
Process Data Process Capability Analysis Total Time
address data compression issues. USL 120.000 ST
T arget * LT
Results/Benefits LSL
Mean 10.825
*
Drastically improved cycle time, decreasing it from an average of 90 to 30
Sample N
10 minutes. Span (longest cycle time) was reduced from 291 to 33 8.15756
StDev (ST )
StDev (LT ) 8.66795
minutes. which lead to dramatic productivity savings for GEAE and ITS.
Potential (ST ) Capability
Because one less technician was required for the PC install Cp process, the *
client achieved a productivity savings of over $83,000 annually, in
CPU
CPL
4.46
*
addition to the cost avoidance of over $90,000 from not having to hire 4.46
Cpk
Cpm *
additional personnel and an extra delivery van as originally scheduled. 0 20 40 60 80 100 120
Also, end users were more satisfied with the overall install process.
Overall (LT ) Capability Observed Performance Expected ST Performance Expected LT Performance
Pp * PPM < LSL * PPM < LSL * PPM < LSL *
PPU 4.20 PPM > USL 0.00 PPM > USL 0.00 PPM > USL 0.00
Increased client’s staffing productivity by $83K while improving performance!
PPL
Ppk 4.20
* PPM T otal 0.00 PPM T otal 0.00 PPM T otal 0.00