Gautham Karthick

What is the methodology that we need to use to convert the VOC (Voice of customer) to Critical customer requirements(CCR)?

Dear Ankit, We need to approach this scenario from two perspectives viz VOC(Voice of Customer), VOB(Voice of business). One point is clear if the customer is unwilling to pay then it becomes an NVA.So does quality.But then, as I pointed out, quality is an implicit requirement which again falls into the purview of VOB. Suppose if you don't inspect, there is every possibility of losing customer goodwill and business as well in case there is a defect. There comes the concept of inbuilt quality (someone pointed about implementing poka-yoke), this would detect any potential errors and avoid them). In a nutshell, if you are able to arrive at the CCR's, establish the indicators and invent methods to check them during the process itself without any additional manpower, time and cost.That point you can eliminate inspection.This is something which is a dream to most of the manufacturing companies.But then as you progress you shall bring a lot of changes. YES ...QUALITY IS AN NON VALUE ADDED ACTIVITY..No doubt!!!

FMEA is a qualitative tool.So there is every likely possibility that the RPN arrived could be debatable.FMEA improvise over a period of time as you collect more data on the defects and analyse them.Cause and effect diagram is a very vital tool for your FMEA.You shall arrive at the best possible things after evaluating them using C&E Matrix.

Hello Manu: I could understand that you are actually finishing a turned part(should be a forged shaft - CK45(must be a medium carbon steel material)). If the spline is hobbed then it should be stub tooth. Then you would be induction hardening the same on the splines,shaft(wherever needed) and then you would be grinding the induction hardened area(except splines) (grinding tolerance should be ranging from 0.022 mm ~ 0.1 mm) After this, i suppose you would be doing a magnetic particle examination for determining the quench cracks. Here's my take on the matter. You should first establish the process by a) conducting a machine capability study (Cm,Cmk) establish the process potential - Pp and Ppk c) Conduct an on-going process capability study (Cp,Cpk) If your cp,cpk is less than 1.67 and more than 1.33 then you would at 3sigma level with 99.73% This is the starting point and you should continue to improve your process in each stage to achieve a Cp,Cpk more than 2.00 It is generally tough because of the inherant variability associated with the material,machine etc., 3 sigma should be the ideal. Hope this should give you some insight. If you need any further info,please revert.

RPN number of 100 is the threshold value and you need to derive action plan for reducing the same.But then,RPN is not only the deciding criteria.If your severity is high and occurence and detection are moderate.Still, you need to derive action plans to reduce the severity rating.Example if your S=10, O=3, D=3 RPN will be 90.As your severity is high, you need to derive your action plans.Hope this helps.

Only when you give the entire data,i would be able to arrive at the correct inference.But then,from the details that you have given,i could figure out that the std dev is around 0.11.You need to reduce your variation as much as possible.Also center the process to the mean. What process is this? Is it a drilling or turning process? Please give more clarity.

How did people arrive that only 3.14 defects are allowed for million opportunities for six sigma? Is there any mathematical/statistical proof for this? Likewise for 3sigma,4sigma and 5sigma?