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1、Analyze Tollgate Review Material Project Name: Small Lot price ImprovementReview Date: Jun 2009,CONFIDENTIAL DRAFT,Improve,Lean Six SigmaDMAIC Improvement Process Road Map,Process Constraint ID and Takt Time Analysis Cause and Effect Analysis FMEA Hypothesis Tests/Conf. Intervals Simple and Multiple
2、 Regression ANOVA Components of Variation Conquering Product and Process Complexity Queuing Theory,Identify Potential Root Causes Reduce List of Potential Root Causes Confirm Root Cause to Output Relationship Estimate Impact of Root Causes on Key Outputs Prioritize Root Causes Complete Analyze Gate,
3、Tools,Activities,Control,Measure,Define,Analyze,Analyze Phase Deliverables,Validated Project Charter,Baseline Process Capability,Confidence Intervals Hypothesis Testing,New Process,Plan & Metrics,D,M,A,I,C,Continuous Y Discrete X,Continuous Y Continuous X,Design of Experiments (Screening),ANOVA Full
4、y Nested ANOVA (Multi-Vari),Scatter Chart Regression Matrix Plot,“Subjective Analysis” Used in Accelerator,“Objective Analysis” Used Post Accelerator (Use tools as required),Brainstorming, etc Cause & Effect Diagram (Fishbone),Cause & Effect Matrix Failure Mode and Effect Analysis Pareto,Idea Genera
5、tion,Narrowing Focus,Critical Few Xs,Value Stream Mapping (Lean focus),Charter Summary,Problem: Pricing for Small lot were lack of controlled and 53% of delivery in 2008 in Suzhou were small lot but GM was 5% digits points lower than average, 1/3 of small lot delivery were negative GM Scope: Commerc
6、ialized order of SEM material selling directly to customer in Asia. Goals:To refine and improve small lot pricing process to increase Gross Margin of small lot product by 5% points.,Problem / Goal Statement,Tollgate Review Schedule,Business Impact,Core Team/Stakeholders,TollgateScheduledRevised Comp
7、lete Define:03/27/09- 03/31/09 Measure:04/17/0905/11/09 05/25/09 Analyze:05/15/0906/02/09 XX/XX/XX Improve: 06/12/0907/10/09 XX/XX/XX Control:06/30/09XX/XX/09 Xx/XX/XX,Philippe XimenaBusiness Champion Alan KuekProject Sponsor Minwei Feng / Toh KS/ David Cai Process Owner Yaoming LeeBlack Belt Hani N
8、oshiMaster Black Belt Core Team Func. % Stakeholder Minwei FengSales10Sales Manager Ying LiuSales 5Sales Jeff YangSales 5CSR Yan TangCSR 5,Customer Impact: Negative Impact Financial Impact of Project: (Type 1): If we succeed to increase 5% GM on small lot, keep 10% revenue of small lot in EM sales i
9、n Asia, we are able to obtain OI benefit: 5% X 10% X 50MM = 250K USD,Analyze,Control Chart,Jan 08, Feb 08, Dec 08 were out of control,Suzhou 2008, 1Q2009,Analyze,Baseline Basic Statistics,1610 Data was analyzed. The current process has a non-normal distribution with the P-Value 0.005. The mean and m
10、edian have big gap, which is - 4%and 14.8% respectively. The range is 750% and the standard deviation is 69%,Analyze,Baseline Basic Statistics,146 Data was collected The current process has a non-normal distribution with the P-Value 0.005. The mean and median have big gap, which is 0.5 and 11.2 resp
11、ectively. The range is 225 and the standard deviation is 35,Analyze,Cause & Effect Diagram,Analyze,1,2,3,3,2,1,2,4,1,4,1,3,Four “1”s are the “Critical Xs” driving Price Score. These are the teams focus going into the Improve phase.,2,GM By Sales, by product line, by lot size, by month,Analyze,Repeat
12、 Order analysis,From Jan 08 to Mar 09, total 689 product, 3,034 delivery, in which 1,610 delivery were small Lot. 51% of shipment were one or two delivery. 43.4% of small lot delivered ONCE. 383 of 689 product (56%) were repeating small lot, without large order. Another 92 products sold only one lar
13、ge lot,Analyze,Linear Regression,95% confident that 97.6% of the variation in Price Score is from the GM % (Overwrite),Analyze,One Way ANOVA by lot size,One-way ANOVA: GM % versus QTTY Source DF SS MS F P QTTY 15 97.075 6.472 26.45 0.000 Error 3018 738.372 0.245 Total 3033 835.447 S = 0.4946 R-Sq =
14、11.62% R-Sq(adj) = 11.18% Individual 95% CIs For Mean Based on Pooled StDev Level N Mean StDev -+-+-+-+- LL10 672 0.1819 0.1804 (*-) LL100 124 0.1397 0.1222 (-*-) LL20 274 0.2178 0.1373 (-*-) LL30 132 0.1790 0.1455 (-*-) LL40 71 0.2204 0.1316 (-*-) LL50 151 0.1334 0.1531 (-*-) SL0 337 -0.3385 1.1064
15、 (-*-) SL1 273 -0.1382 0.6561 (-*-) SL2 210 -0.0863 0.6541 (-*-) SL3 155 0.0533 0.4130 (-*-) SL4 63 0.1303 0.3419 (-*-) SL5 425 0.1407 0.2524 (-*-) SL6 55 0.1699 0.1968 (-*-) SL7 35 0.2979 0.3441 (-*-) SL8 34 0.1509 0.2184 (-*-) SL9 23 0.1690 0.8539 (-*-) -+-+-+-+- -0.25 0.00 0.25 0.50 Pooled StDev = 0.4946,Because the p-value = 0.05, we can be confident that Lot Size do have an impact GM%.,Analyze,One way ANOVA test by Month,One-way ANOVA: GM % versus Month without Noise (Jan, Feb, Dec) Source DF SS MS F P Month
