July 2016 - Volume 2, Issue I
SIX SIGMA
GREEN
BELT
PROJECT
By:
QURRATULAIN SHAKOOR
Vice Chairperson - PSIE
This project was about developing a solution towards
increased scrap generation for a tobacco grade (SF2RWS)
due to degradation in primary conditioning cylinder in the-GLT
Factory, British American Tobacco Company (BAT) . Scrap
generation is one of the contributing factors in reducing the
quality of the tobacco grades. The average scrap per sample
was 13.5%.
The critical tools used in this project were; SIPOC diagram,
XY Matrix, Descriptive Study, Minitab for Process Capability,
Cause and Effect diagram, hypothesis testing, Correlation/Regression analysis, DOE, and solution plan.
In the DEFINE phase, after problem identification, a project
charter was created and approved from the executives of the
company, followed by a SIPOC diagram and Process Map to
provide detailed information about the whole manufaturing
process.
In the MEASURE phase we studied the actual scenario of the
problem and data was captured for analysis. Through descriptive study and process capability tools we made a conclusion
on current scenario. Result of data was analyzed through
correlation analysis and hypothesis testing in the ANALYSIS
phase. It showed that the critical parameters of primary conditioning cylinder needed to be optimized and reassessed for
tobacco grades which will help in reducing the roller deck
scrap generation.
In the IMPROVE phase solution was implemented with the
help of DOE and we observed reduction in the scrap generation (an improvement of 10%)
In the CONTROL phase a plan was created and shared to
maintain the gains.
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