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Question:

Analyse the production process based on the data provided. Do a Supplier-Inputs-Process- Outputs-Customers (SIPOC) Chart Analysis to propose what a buggy tank manufacturing process would involve regarding critical information and key stakeholders of the manufacturing operations. Refer to Six Sigma Week 3 Lecture Notes for a detailed overview of SIPOC Chart Analysis.

 

Answer:

Introduction

The study aims to devise a SIPOC diagram for an off-road buggy. This diagram has analysed the process of production as per the information provided in the case study. The SIPOC chart has considered the critical information which are in the best interest of the key stakeholders and manufacturers. The given model has been identified with the problem of non-identical fuel tanks which are present on the either side of the buggy. Moreover, the fuel system is normally depicted with off shelf fuel pump and plumbing. However, the scope of the SIPOC is depicted with fabrication of the fuel tanks only. The present diagram suggests all the relevant process which are required for the interaction between tier 1 suppliers and also transformation of the operation at the end user. This is done by including the relevant discussions pertaining to Suppliers, inputs, process outputs and customers.

Supplier, Inputs, Process, Outputs, and Customers (SIPOC) Diagram

Suppliers

The main supplier of the off-road buggy has been discerned in terms of The Job Shop

Inputs

  • Fuel Tank- It needs to be discerned that the off-road buggy comprises of the two fuel tanks one on either side of chassis. These are further discerned with steel sheet with 2mm thick. The fuel tank is seen to include the filler cap, a fuel outlet port and a breather port. In addition to this, the fuel tank is seen to be fitted with a leak filler cap.
  • Chassis
  • Vent Pipe
  • Leak-proof filler cap- 1 tank per 2.5 min
  • Baffle Plates
  • Laser cutter-1 Laser cutter (42mm/sec cut, 30 sec load and 30 sec unload)
  • Folding machine- 1 Folding machine (1 fold per 15 sec)

Process

  • Cutting using the Laser Tool- Total Process time of 3 minutes
  • Folding- Total Process time of 1 minute
  • Tacking and filling corners- Total Process time of 3 minutes
  • Identifying and eliminating the waste in production-
  • Leak Testing- 1 tank per 2.5 min
  • Rework with grinder and manual welder- Total Process time of 5 minutes
  • Final inspection- 1 min per part

Output

  • Increased sales volume by 20%- The process optimisation will be able to increase the overall volume by 20%
  • Identical mirror reflection of each other in fuel tanks- To correct the present problem of not identical mirror reflection
  • Increasing the buddy sets per week- Following production rate of 10 buggy sets per week

Customer

  • Quality- Improved quality will be evident in form of more flexibility in terms of fabrication of the fuel tanks
  • Speed
  • Better Design- The improved design will be evident with identical fuel tanks
 

Bibliography

Bevilacqua, M., Ciarapica, F.E., De Sanctis, I., Mazzuto, G. and Paciarotti, C., 2015. A Changeover Time Reduction through an integration of lean practices: a case study from pharmaceutical sector. Assembly Automation, 35(1), pp.22-34.

Cheung, Y.Y., Goodman, E.M. and Osunkoya, T.O., 2016. No more waits and delays: streamlining workflow to decrease patient time of stay for image-guided musculoskeletal procedures. RadioGraphics, 36(3), pp.856-871.

Conger, S., 2015. Six sigma and business process management. In Handbook on Business Process Management 1 (pp. 127-146). Springer, Berlin, Heidelberg.

Darwish, A., 2017. SIPPOOC (SIPOC Plus) An Extended SIPOC. Business Process Management.

Grover, A.K., Chopra, S. and Mosher, G.A., 2015. Adoption of Food Safety Modernization Act: A Six Sigma Approach to Risk Based Preventive Controls for Small Food Facilities.

Mishra, P. and Kumar Sharma, R., 2014. A hybrid framework based on SIPOC and Six Sigma DMAIC for improving process dimensions in supply chain network. International Journal of Quality & Reliability Management, 31(5), pp.522-546.

Sharma, R., Gupta, P. and Saini, V., 2018. SIX SIGMA DMAIC METHODOLOGY IMPLEMENTATION IN AUTOMOBILE INDUSTRY: A CASE STUDY 2. Journal of Manufacturing Engineering, 13(1), pp.042-050.

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