Six Sigma Project Case Study Overview by Master Black Belt Steven Bonacorsi, International Standard for Lean Six Sigma (ISLSS). General Electic ACFC "At the Customer, for the Customer"

1. Six Sigma DMAIC Project
GE Aircraft Engines Account
Project Leader/Green Belt: Dave Smith
Project Leader Title: Solution Design Consultant
Project Start Date: May 21, 2003
Master Black Belt: Steven Bonacorsi

2. Six Sigma in Action
Work Order Error Correction
Customer Profile – 17,000 Seat, Global design & production company for Aircraft Engines
Business Problem & Impact Process Capability – Before
Fixed assets work order scanning (barcode) inherently introduces errors.
Multiple individuals use the existing process, which causes 40 - 50% 65 (9%)
error rate. The existing process is not cost effective, since errors are Defects
628 (91%)
corrected manually. Successful
Measure & Analyze
Data Collection:
Historical data was collected over a 1 month period to quantify the extent
of errors. Z_ST = 1.3
Root Causes:
Serial Numbers for IBM T30 laptops and DELL monitors fail import every
time and barcode being different between the shipping box and
equipment were determined to be root causes. Process Capability – After
Improve & Control Baseline Improved
Real Time scanning was implemented to in December 2003. Scanner Units 693 240
accuracy will be monitored daily and control charts will be used Qrtly to
Defects 85 0
validate process improvements.
DPMO 93,795 0
Results/Benefits Z (ST) 2.82 6.0
At the end of the project, real time scanning reduced rework 100% and
cycle time per hardware component reduced from 10 to 5 seconds Z (LT) 1.32 4.5
resulting in annual efficiency savings of >9.7 K!
A savings of US $9,716 in 2003!