By,

Kavitha Reddy
Gurrala,
Senior Manager QA
• Competitive Pressure
• Legitimate means to improve-
Processes, Products, Services &
thus Financial Performance.
• Tools & Concepts for Improvement
Projects.
It is a disciplined, statistical-based, data-
driven approach and continuous
improvement methodology for
eliminating defects in a product, process
or service.
Six Sigma is a Management Philosophy
focused on Business Process Improvements to:
• Eliminate Waste, Rework & Mistakes
• Increase Customer Satisfaction
• Increase Profitability & Competitiveness

Six Sigma can be also defined as a Statistical

Measure to objectively evaluate processes for
Continual Improvements.
• TO REDUCE VARIATION
• TO REDUCE DEFECTS
• TO IMPROVE YIELD
• TO ENHANCE CUSTOMER SATISFACTION
• TO IMPROVE THE BOTTOM LINE
A Defect is any variation of a required characteristic of
the Product which is far enough from its target value
to prevent the product from fulfilling the Physical &
Functional Requirements of the Customer.

It is anything that dissatisfies a Customer.

 Y=f(X)
Define
Measure
Analyze
Improve
Control
22
 PrOJECT CHARTER
Project Charter
Project Name Improvement of Moisture Consistency within CHP GN
Process Name Industrial Mixing
Sub Process Name Chemicals Delivery for Industrial Mixing
Department Head Mr.C.Nehruji
Six Sigma Green Belt Ms.Kavitha Reddy Gurrala
Ms.Uma (NHP & CHP GN QC)
Project Team K.Bhasker (Contractor)
B.Shiva Rama Krishna (Contractor)
Business Case Problem/Opportunity Statement Goal Statement
CHP GN Facility serves as an ancillary to
Variation in Moisture Levels of Negative Reduce the Batch to Batch Variation in Moisture
NCPP Production and it produces the
Active Material leading to Poor Briquette Levels that are consumed for production of a
Negative Active Material for Battery
Formation & Loose powder Generation Single Customer Order
Production.
Project Scope Includes Project Scope Excludes Project Mile Stones
Start Date: 1-Jun-18 End Date:
Target Date Actual Date Review
The Project concentrates on managing The Project Excludes management of the Define 8-Jun-18 11-Jun-18 12-Jun-18
the flow of only Liquid Components Flow of the Solid Components that are Measure 22-Jun-18 22-Jun-18 23-Jun-18
that are added to the Mixture added to the Mixture Analyze 29-Jun-18 30-Jun-18 14-Jul-18
Improve 20-Aug-18 1-Sep-18 1-Sep-18
Control 30-Sep-18
Process CTQ Details
Project Charter Sign Off
Current Target
UCL LCL
SPC to be centered between 3.172 2.745 Project Leader
Ppk 0.69 1 Green Belt

DEFINE
23
Project Problem and Scope
Variations in Moisture Levels between CHP GN
batches is leading to poor BRIQUETTE
formation & Loose Powder Generation.

The Project would focus on Improving the

Industrial Mixing Process used for CHP GN
Production.

DEFINE
24
Business CASE
Relevant Metrics: Statistical Process Control Charts, Cpk
& Ppk

Improvement Targets:
• To ensure that the SPC chart provides a good estimate
of the Process Average
• To achieve a Ppk value of 1 & above

Operational Impact:
• Briquette Strength Improvement
• Reduction of Fines Generation at Briquetting.

DEFINE
25
ROLES & TEAM MEMBERSHIP
Project Leader: Mr.C.Nehruji
Green Belt: Ms. Kavitha Reddy Gurrala
Team Members: Ms. Uma (QC)
Mr. K. Bhasker (Contractor)
Mr. B. Shiva Rama Krishna (Contractor)

DEFINE
26
 PROJECT PLAN
1-Jun-18 8-Jun-18 15-Jun-18 22-Jun-18 29-Jun-18 6-Jul-18 13-Jul-18 20-Jul-18 27-Jul-18 3-Aug-18 10-Aug-18 17-Aug-18 24-Aug-18 31-Aug-18 7-Sep-18 14-Sep-18 21-Sep-18 28-Sep-18
Planned
Define
Actual
Planned
Measure
Actual
Planned
Analyze
Actual
Planned
Improve
Actual
Planned
Control
Actual

DEFINE
27
Define
Measure
Analyze
Improve
Control
28
 DATA COLLECTION
Scenario

• Data Collection was done for the

Manual Chemical Loading Process

• Moisture was collected from a total

of Nine Batches produced by Three
different Manpower within the
Plant.
MEASURE
29
 MOISTURE DATA
Moisture Upper Spec 4 Lower Spec 1

Batch # 1 2 3 4 5 Sample X Bar R

1805045 3.06 3.21 3.21 3.27 3.27 1 3.204 0.21

1805043 2.77 3.21 3.05 3.28 3.25 2 3.112 0.51

1805042 3.66 3.72 3.7 3.58 3.77 3 3.686 0.19

1805040 3.51 3.62 3.71 3.58 3.49 4 3.582 0.22

1805053 2.88 2.33 2.38 2.11 2.38 5 2.416 0.77

1805055 2.48 2.82 2.52 2.72 2.75 6 2.658 0.34

1805047 3.09 2.74 3.07 2.88 3.07 7 2.97 0.35

1805048 2.87 2.9 2.83 2.58 2.9 8 2.816 0.32

1805051 2.08 2.32 1.92 2.26 2.34 9 2.184 0.42

XBar Bar 2.958666667 R-Bar 0.37

MEASURE
30
Define
Measure
Analyze
Improve
Control
31
 Moisture Level Analysis
Xbar-R Chart of Moisture Based on the SPC
1
1
3.6

1
Chart, the Process is
3.2
Sample Mean

UCL=3.172

2.8
__
X=2.959 out of Control, as it
LCL=2.745

2.4 1
1
cannot provide a good
2.0
1 2 3 4 5 6 7 8
1

9
estimate of Process
Sample
Average. Thus, the
0.8 UCL=0.7824
Moisture Levels
0.6
within the CHP GN
Sample Range

_
0.4 R=0.37

0.2
produced are not
0.0 LCL=0 Consistent &
1 2 3 4 5 6 7 8 9
Sample Predictable.
ANALYZE
 Moisture Level Analysis
 As the Process is out of Control
there is a difference between Cpk &
Ppk Values, It indicates that the
Overall Capability can be
improved if the variation between
Batches is reduced.
 Also Cp & Cpk are not almost
similar, that indicates that the
process cannot produce Moisture
Levels near to a Central Value as
they are running too close to USL
 As Ppk is only 0.69, the overall
capability of the process to produce
CHP GN with Moisture Levels as per
CS can be further increased by
reducing the variation in Moisture
Levels between the CHP GN
Batches.

ANALYZE
Define
Measure
Analyze
Improve
Control
34
 SEMI-AUTOMATION
• Implementation of a trail setup to
ensure uniform flow of liquid
ingredients into the Mixing Chamber
with the dry ingredients.
• Moisture Levels were captured for
the R&D batches produced with the
trail setup

IMPROVE
35
 SEMI-AUTOMATION

IMPROVE
36
 Result's

Conclusion: Moisture consistency levels and Process Capability levels have

improved drastically after manual addition of Liquid Ingredients for
Chemical Mixing was avoided with the new setup.
IMPROVE
37
Define
Measure
Analyze
Improve
Control
38
 Measures
• Need to ensure that batches are
uniformly dried after the mixing
process.
• In order to use the set-up for regular
production, timers need to be added
for each solution flow.

CONTROL
39
Thank YOU

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