Improve the Lay-Up Process by Reducing 15% of the Documentation Errors within Six Months using Kaisen and/or DMAIC Six Sigma Tool

Abstract

From August 2017 to October 2017 (3Q2017) the documentation errors (including layup errors and mixed styles) were 96% average in one Distribution Center at the west coast. DMAIC methodology was applied including lean principles to find the root cause of these documentation errors. A Kaizen exercise was executed to identify potential solutions to improve the current process. During the Kaizen exercise a SIPOC diagram was used to identify all relevant elements that can support the improvement of the process. As a result, layup error category was targeted to be improve because has a lot opportunities. Cause-and-effect relationship (fishbone diagram) was used to identify a range of potential solutions to the problem. Solutions were evaluated and prioritized by using a Pick Chart. Five actions items were proposed for improvement and a reduction of 17% was reached for the documentation errors (including layup error and mixed styles categories). Also, an increase of 24.70% for the Output per Hour (OPH), a reduction of 34.78% from shrink and an increase of 0.02% in the accuracy data. These results support to achieve the 15% goal of layup documentation errors reduction proposed by this project within 6 months period. Key Terms - Accuracy Data, DMAIC, Kaizen, KPI’s, Lay-up Process, Lean Principles, OPH, Pick Chart, Shrink, SIPOC.