Introduction: For my black belt project I decided to look at the reducing the lead times for lab tests that are conducted within our Micro and Quality Control lab on site. If these tests are delayed or their paperwork is delayed then it can have an affect on when our batches can be released. The tests we have identified are TOC (Total Organic Content), Endotoxin, sterility testing and bioburden testing. In the define stage we want to define what our actual problem is so we can progress through the other DMAIC stages. We will know our true cost savings after the measure phase but so far we have identified a cost saving of €14,000 per quarter based on no weekend work for our QC personnel.
The graph in Fig 1 below shows the estimated cost savings based on what we know of the lead times in the define stage.
Fig 1 
In the define stage also we must define our team. I am from our LSS group. We will have a planner/logistics person, QC lab personnel, Micro personnel and with guidance from the LSS lead. IT Sligo will be providing a mentor for me for the duration of the project. A SIPOC was then conducted for the project. This lists out what suppliers, inputs, processes, outputs and customers are involved within this project scope. See Fig 2 below. A VOC (voice of the customer) was drawn up and then sent out to relevant people within the different functions on site. The questions in the VOC will tell us what is good and bad with the current process. Also there is a question which asks what the "blue sky" ideals would be if money and resources were not an issue. See Fig 3 below.
A high level process map is shown in Fig 4 below which was developed from the SIPOC mapping.
A gantt chart below shows the various DMAIC timelines that are laid down for this project. They were given to us from IT Sligo. See Fig 5 below.
Fig 5 
No comments:
Post a Comment