Alcoa Six Sigma

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Six Sigma Project S I X S I G M A D M A I C T Reduce “Dimensional” Rejections Related to Grinding Process on Precision Aerospace Fasteners Son D Tran, Director of QA, AFS - Industry Operations 1 Reduce Dimensional Variation - Define D M A I S I X S I G M A C T DMAIC REVIEW CONTROL DEFINE IMPROVE MEASURE ANALYZE Develop charter Map the process Understand the voice of the customer 2 Reduce Dimensional Variation - Define D M A I S I X S I G M A C T Project Overview : Business Case Internal rejections of Titanium products cause significant scrap, rework and customer returns. This level of rejection has affected our Key Performance Indicators (KPI), customer backlogs, and Quality and Delivery Performance ratings to major OEM (Original Equipment Manufacturer). Reduction of Internal rejections will increase customer satisfaction and improve our KPI. Problem Statement Dimensional rejections related to the Grinding process(es) of Titanium Hi-Lok in Cells 131, 132 and 133 attributed to about 2% rejections of total pieces completedto-store the last seven months (Sep 01- Feb 02). This attributed to monthly scrap loss, plus significant rejections at subsequent processes (i.e., Thread Roll), and increased in rework and customer returns costs. Goal Statement Reduce dimensional rejections related to Grinding process(es) in Cell 131, 132 & 133, by 50% from current FPY base-line plus annual reduction in scrap cost of 30% end of August fiscal year 2002.. 3 Reduce Dimensional Variation - Define D M A I S I X S I G M A C T Customer Needs / Requirements ● ● ● Key Internal customers for Work Cells 131, 132 & 133 are Thread Roll Department and Inspection. External customers are major OEM. Customers are expecting to receive products (ground parts or finished parts)

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