Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Allen Mackay
Mgr. MMQA Saudi Arabian Airlines
INVENTORY MOVEMENT FMSZ
Green Belt Project
Six Sigma
A Project Review
SV MM
SV MM OVERVIEW
SIX SIGMA
5 Phases of training
GE 6-Sigma Greenbelt
1. Define
2. Measure
3. Analyze
4. Control
5. Improve
DEFINE PHASE
EXAMPLE…TODAY
Expendable Materials
FAST MEDIUM SLOW ZERO TOTAL
Qty SR Qty SR Qty SR Qty SR Qty SR
What could be
causing high levels of
SLOW and ZERO
moving stocks ?
Constraints
Defect(s)
Project High Level Program Plan • When EXPENDABLE ‘FM’ inventory is
M: All Procurement areas
A: Select the area with most opportunity
<QQ% by quantity
I: Define methods to improve • When EXPENDABLE ‘FM’ inventory is
C: Define methods of control <VV% by value.
Data Sources
• MEMIS using various focus reports
• TIS using focus reports
• PC’s of AOG Desk
OVERVIEW OF PARTS
Y2000 PABCD [Expendable] >6 Sigma<
800,000 120%
2000
719,024
700,000 98%
100% 100%
85%
600,000
QTY of ITEMS
80%
Percentage
500,000
70%
400,000 60%
300,000
40%
200,000 151,255 133,534
20%
100,000
18,798
0 0%
60% 80%
70%
50% 70%
50%
Percentage of TOTAL
RISK ASSESSMENT
INCLUDES EXCLUDES
What All Expendable Materials All Repairable, Rotables,
Uniforms, Stationary
Where All materials located in MM All materials that have been
areas of responsibilities issued to Customers, but not yet
returned.
When All time frames where None.
materials have been bought
since the airline started.
Who MRP & IC SFPS
TSV Planning VP MM office
Stores MM Support.
Procurement
MMIS
TSV
Proc 10%
13% 18%
MR P
Stores
18%
I/C
MEASURE and
ANALYSE
PHASES
0 10 20 30 40 50 60
Cpm 0.09
(35 width)
Overall Capability Observed Performance Exp. "Within" Performance Exp. "Overall" Performance
Pp 0.18 PPM < LSL 1000000.00 PPM < LSL 999977.82 PPM < LSL 887807.12
PPU 0.76 PPM > USL 0.00 PPM > USL 0.00 PPM > USL 11281.93
PPL -0.40 PPM Total 1000000.00 PPM Total 999977.82 PPM Total 899089.05
Ppk -0.40
34 36 38 40 42 44 46 48 50
Cpm 0.19
(2 width)
Overall Capability Observed Performance Exp. "Within" Performance Exp. "Overall" Performance
Pp 2.05 PPM < LSL 1000000.00 PPM < LSL 999958.71 PPM < LSL 999958.71
PPU 5.42 PPM > USL 0.00 PPM > USL 0.00 PPM > USL 0.00
PPL -1.31 PPM Total 1000000.00 PPM Total 999958.71 PPM Total 999958.71
Ppk -1.31
VARIENCE (Zshift)
Descriptive Statistics: (%)SR
Poor 3.0
Zst = 6.15 Poor control Need better
Poor factory control
Zlt = -1.20 Technology is
fine
Zshift = 7.35 A B
Zshift 1.5
Control C D
Control is fine World
Bad factory or Class
technology
Good Goal
0 3 6
Zst
Poor Good
Technology
CONCLUSIONS
1. With P value = 0.000 (less than 0.05) shows they are statistically significant.
2. The means in (2) are significantly different.
3. (SS area / SS Total)* 100 = % variation explained by "Groups"
· (28654.55 / 29365.84)*100 = 97.58%, therefore if we correct
the differences in 'Groups' we should expect to see our
variation go down by 97.58%.
Saudi Arabian Airlines/GEAE Partners in Productivity 21
GE Aircraft Engines
70
60
50
(%)SR
40
30
20
10
0
new new new new old old old old
fast medium slow zero fast medium slow zero
Group
IIC
SE
e
al
rd
nt
s
m
nt
er
.. .
da
la
G
ra
ne
rm
en
rp
an
rf
1.00E+11
po
we
ifo
Ai
G
St
m
Un
Po
Co
Airframe Proc 0
BC
P20
P21
P22
P23
P24
P25
TOTAL IICs - WITH SD's
2000
1500
QTY
1000 Buyer 21
500
0
P22 P23 P21 P20 P24 P10 P25
SD IIC's 1642 1325 1075 1008 767 492 481
BUYER CODES
Airframe Buyers
IMPROVE PHASE
Procurement
Market Research Place order to buy. (Small %
have an MRP plan) Weak monitoring
Under stock occurs
and
MEMIS measuring
NEW METHOD
NEW METHOD for “EXPENDABLE MATERIALS” Planning and Procurement
Parts arrive at Stores
MOS issue PC report for Issue & accept back
Stores or Direct delivery
AOG’s by Buyer Code “unused” qty
(MEMIS updated)
TIS
Produce Major Open Item (MOI) weekly SD Report
Feedback
Improved Process
CONTROL PHASE
What Xs to Control
Variation Control
Project Closure
Project Dates
Started: Oct 2000 Completed Sep 2001
Improvements Implemented Oct 2001
Description of Savings
Reduction in Stock Depletes, by improved math model for “reorder &
under stock levels” settings & “solving Major Open Items (MOIs)”.
Savings Calculation For Buyer Code 21
Time of Aircraft Delay due to SD part…………….. Equals = SR xxxxxxx
Project Signatures
7000
6000
5000
Quantity
4000
3000
2000
1000
0
8Sep01-Started 15Sep01-Current
Series1 7501 2891 4610
Reduction (61%)
Awaiting next monthly report to show FMSZ impact.
Quantity
2500
will become apparent with 2000
the monthly Focus Reports 1500
from MEMIS. 1000
BEST GUESS ?
FINALLY
DO GET INVOLVED IN
SIX-SIGMA
The benefits will
surprise you!