using six sigma methodology to create a kiln drying workshop

Using Six Sigma Methodology to Create A Kiln Drying Workshop

FPS 60th International ConventionExtension & Technology Transfer Group

K. Josephine PaviaFrancis G. Wagner and Rick L. Edgeman

FPS 60th International Convention - Extension & Technology Transfer - K. J. Pavia

Purpose of this Endeavor

How can we build a quality outreach workshop in a very short time span?

&

How do we quantify our efforts?


What is 6σ?

Six Sigma is a highly structured strategy

for acquiring, assessing, and applying customer, competitor, and enterprise

intelligence for the purpose of product, system

or enterprise innovation and design. (Edgeman 2005)


The application of Six Sigma focuses on the design or redesign of products and services and their enabling processesso that from the beginning customer needs and expectations are fulfilled.

This is also known as Design for Six Sigma or DFSS.

(Edgeman 2005)


UI-Inland Empire Kiln Drying Workshop

There are 3 engines to Six Sigma

Pande et al 2002

FPS 60th International Convention - Extension & Technology Transfer - K. J. PaviaPande et al 2002

DefineMeasureAnalyzeImproveControl

DefineMeasureAnalyzeDesignVerify

Six Sigma Acronyms

Pande et al 2002

Pande et al 2002


Define the project:oDevelop a clear definition of the project.

oDevelop organizational change plans, risk management plans, and project plans.

Define the project:oDevelop a clear definition of the project.

oCollect background information on the current process and your customers’ needs and requirements.

DMADVDMAIC

DMAIC vs. DMADV


Defining the Project

Similar to a proposal:• Project objectives• Project scope• Business case• Roles &

Responsibilities• Assumptions &

Limitations

Six Sigma Difference:• Gaant charts

• PERT charts

• COPIS Model

• Organizational Change Plans


Defining the ProjectSix Sigma Difference:

• Gaant charts

• PERT charts

• COPIS Model

• Organizational Change Plans

Six Sigma COPIS Model

Customers Suppliers

Outputs InputsProcess

Steps

Q: Does anyone currently use Gaant charts to quantify field time to their bosses?


DMAIC vs. DMADV

Measure customer requirements:

oCollect the Voice of the Customer (VOC) data.

oTranslate the VOC into Critical to Quality requirements (CTQs)

oDevelop a phased approach if necessary

Measure the current situation:

oGather information on the current situation to provide a clearer focus for your improvement effort.

DMADVDMAIC


DMAIC vs. DMADV

Measure customer requirements:

oCollect the Voice of the Customer (VOC) data.

oTranslate the VOC into Critical to Quality requirements (CTQs)

oDevelop a phased approach if necessary

Measure the current situation:

oGather information on the current situation to provide a clearer focus for your improvement effort.

DMADVDMAIC

’05, ’06, ‘07 UI-IEKD Workshops


Eliciting the VoC

The Voice of the Customer (VOC) is aggressively sought and rigorously evaluated

and used to determine needed outputs and hence the optimal process configuration needed to yield those outputs and their necessary inputs for which the best

suppliers are identified and allied with.

From Concept to Market: the Voice of the Customer

(Edgeman 2005)


Eliciting the VoC

Tools:• Customer Segmentation

Tree• Benchmarking• Elicitation via interviews,

contextual inquiry, focus groups, surveys

• VoC table• Kano Model• QFD Matrix

Kiln RelatedSuppliers

Kiln Structure Suppliers

Kiln Accessory Suppliers

Boiler Support Suppliers

Lateral Experts

UI Faculty

Kiln Workshop Coordinators

Other Workshop Coordinators

Mills w/ kilnsOwners / CEOs

Section Supervisors

Kiln Operators


Eliciting the VoC





Benchmarking is the process of continually searching for the best

methods, practices and processes, and either adopting or adapting

their good features and implementing them to

become the “best of the best.”

(Edgeman 2005)


Why Benchmark?

Time

Per

form

anc e

Expectations

Continuous Improvement

Performance Gap

(Edgeman 2005)


Benchmarking for Fees & Inclusions

--

303040

Class Size Limit

$55$25

Late registration

fee

2$375U Id (prev)4$25$395SUNY

$75$395U Minn4$350PSU 1all$650OSU

Meals IncCancellation

feeRegistrationSchool

Measure

Benchmarking was used to determine fees & inclusions for the 2005 UI-IEKD Workshop!

4$45

(10%)2 weeks($0/all)32$450U Id (2005)


Eliciting the VoC


Tree• Benchmarking • Elicitation via interviews,



Advantages / Disadvantages

Gemba symbol (Mazur, 1997)


Eliciting the VoC






Eliciting the VoC




• VoC table• Kano Model• QFD MatrixAKA: E

licite

d Attribute W

eights


Weighting the VoC

Customer Importance Weights:• Linear scale (Likert 1-7)• Quadratic (0,1,3,9)• Constant Sum (divvy a 100 points)• Conjoint Analysis


Part of a QFD Matrix

4450SUM:

--003Feasibility

0+002Relevant contents

+0+02Visual aids

++002Clear

organization

+++03Clear information

Color Materials

Laptop CD-Rom

Better page settings

Ref(OSU03)WtCTQ

Matrix 1: Binder


DMAIC vs. DMADV

Analyze concepts:oGenerate, evaluate, and select the concept that best meets the critical-to-quality (CTQ) characteristics within budget and resource restraints.

Analyze to identify causes:

oIdentify the root causes of defects.

oConfirm them with data.

DMADVDMAIC


DMAIC vs. DMADV

Analyze concepts:oGenerate, evaluate, and select the concept that best meets the critical-to-quality (CTQ) characteristics within budget and resource restraints.

DMADV

2005 Workshop starting budget:☺ ☺ $8.42 ☺ ☺


Select Concept

Random example from the web


DMAIC vs. DMADV

Design:oDevelop the high-level and detailed design.

oTest the design components.

oPrepare for pilot and full-scale deployment.

Improve:oDevelop, test, and implement solutions that address the root causes.

oUse data to evaluate results for the solutions and the plans used to carry them out.

DMADVDMAIC


DMADV

Design:oDevelop the high-level and detailed design.

oTest the design components.

oPrepare for pilot and full-scale deployment.


DMAIC vs. DMADV

Verify design performance:oConduct a pilot test, and stress-test and debug the prototype.

oImplement the design.oTransition responsibly to the appropriate people in the organization.

oClose the team.

Control:oMaintain the gains that you have achieved by standardizing your work methods or processes.

oAnticipate future improvements and make plans to preserve the lessons learned from this improvement effort.

DMADVDMAIC


Presentation Evaluation Form Results

2.882.94Kiln Equipment53.233.37Kiln Support Systems43.423.40Lab / Tour / Offsite33.483.58Kiln Logistics23.533.61Wood Academics1

Mean Presenter

Quality

Mean Subject Matter

CategoryRank

Verify (2005 test run)

Scale of 1 to 4


Bottom 5 Presentation Evaluation Results

Verify (2005 test run)

Scale of 1 to 42.532.58Kiln Pneumatic

Maintenance27

2.322.68Moisture Meters262.682.74Steam Traps25

2.722.83Lab Kiln Run –Measurements24

3.053.00Kiln Pneumatic Controller Troubleshooting23

Mean Presenter Quality

Mean Subject MatterLecture / PresenterRank


Bottom 5 Presentation Evaluation Results

Verify (2005 Pilot test)

Scale of 1 to 42.532.58Kiln Pneumatic

Maintenance27

2.322.68Moisture Meters262.682.74Steam Traps25

2.722.83Lab Kiln Run –Measurements24

3.053.00Kiln Pneumatic Controller Troubleshooting23

Mean Presenter Quality

Mean Subject MatterLecture / PresenterRank

Disclaimer: Coordinator assumed all responsibility for the failure to meet needs of participants. There was general breakdown in securing and training quality/dynamic speakers and/or gathering visual aids for these topics. This information should not be used adversely against those who volunteered to help the UI.


Conclusions1. DMADV engine of Six Sigma focuses on the

redesign of products and services and their enabling processes so that from the beginning customer needs and expectations are fulfilled.

Pande et al 2002




2. Eliciting and Weighting of VoC will be the focus of my PhD research.

3. U Of Idaho-Inland Empire Kiln Drying Workshop is October 2-7, 2006. See web for more details:

☺ Hopefully,




2. Eliciting and Weighting of be the focus of my PhD research.

3. U Of Idaho-Inland Empire Kiln Drying Workshop is October 2-7, 2006. See web for more details: www.cnrhome.uidaho.edu/forp


References1. Ginn, D., B. Streibel, and E. Varner. 2004. The Design for

Six Sigma Memory Jogger. BOAL.QPC, 12B Manor Parkway, Salem, NH 03079-2862, www.goalqpc.com. ISBN 1-57681-047-X. pp.266.

2. Mazur, G. 1997. Voice of Customer Analysis: A Modern System of Front-End QFD Tools, with Case Studies.Proceedings of ASQC 1997. Orlando. May 5-7. www.mazur.net

3. Pande, P.S., R.P. Neuman, and R.R. Cavanagh. 2002. The Six Sigma Way Team Fieldbook: An implementation guide for process improvement teams. McGraw-Hill, Two Penn Plaza, New York, NY 10121.


Special Thanks

DFSSclass

IEDKA Members

UI Faculty & Staff


The End

Any Questions?

using six sigma methodology to create a kiln drying workshop

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