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ADM80003 Six Sigma

tag 0 Download 4 Pages / 844 Words tag 07-07-2021

Question:

An off?road buggy original equipment manufacturer (OEM) has decided to outsource the production of a particular subassembly of their buggy. The outsourced production job shop is a small sized privately owned business that shall be referred to as “The Job Shop” with limited machine and labour resources. The OEM initially requested a small scale production volume, but with the likely possibility of expansion if sales volume increases with their initial design.  This increase in sales volume is forecast based on achieving a 20% cost reduction in the subassembly.  It is expected that over time this will be achieved by identifying and eliminating all of the waste in the production operations and by further streamlining the value added processes.
 
However there is scepticism from the OEM that the production order fill rate can be achieved. Your task is to 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. 

The fuel system of the off?road buggy is comprised of two fuel tanks, one on either side of the chassis. The fuel tanks are made from steel sheet that is 2mm thick. Within each tank is a set of baffle plates that are made of 1mm thick steel sheet. The fuel tank also includes a filler cap, a fuel outlet port and a breather port. The fuel tank is fitted with a leak?proof filler cap. The fuel tank must be vented out to the atmosphere.
 
The vent pipe (breather valve fitting) is located on the upper surface on the tank, very close to a corner. This vent valve acts as a non?return valve to the fuel system. The baffle plates in the fuel tank reduce sloshing of fuel in the tank. Fuel tanks on either side of the buggy are not identical, they are a mirror reflection of each other and hence are two separate assemblies.  The fuel system would normally come with an off?the?shelf fuel pump and plumbing parts, but the scope of this analysis is limited to the fabrication of the fuel tanks only (with only the pipe fittings.
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