Manufacturing Black Belt On Site Support – Inserter DOE Week 1

Event Consultant: Lynn Clark

Event Description: Inserter DOE Prep

Event Location: Baldwinsville, NY


Problem Statement:

Since the _____, the 227 Inserter has a FPY of XXX. This has resulted in ________ at a cost of $_________.

Week 1 Actions:

Charter preparation

  • Scope the project
  • Team
  • Goals

Develop project plan – “Modified Affinity” method

Prepare SIPOC

Conduct preliminary C&E matrix

Start development of questions and hypothesis

Project Scope: 

Analysis conducted during scoping showed that the 227 line has about X% of the overall ________ for all of the inserters. Of the X different ______ defect codes, X% are related to a partially ________ liner.



Project Plan: 

A high level project plan was prepared listing the tasks and an estimated timeline with the projected completion date set for September 2017. There are a number of conditions which may be encountered that may impact the overall timeline. Critical tasks include:

  • Timely capture of Y data (defects per day)
  • MSA
  • Time lag between making adjustment to inputs like temperature and response

C&E Matrix: 

A quick C&E matrix was conducted. Two criteria were used: _____ defects at X; internal _____ related scrap. During the preparation of the C&E it was recognized that both criteria had nearly the same relationship, so only the defects at X were evaluated. 

Next Steps:

Plan FMEA, select team members, reserve the date, start data collection of Y data, and collect and analyze Q1 measurement data.


Many of initial deliverables started or completed. Charter, paretos, SIPOC, C&E, project plan, initial hypothesis statements

Define your Problem Statement.

The first step towards breaking your organizational log jams is identifying and verbalizing the challenge you're facing. What are you trying to solve? This simple Problem Statement exercise can have profound implications for your team. It helps you define the issue and gives TGG some sense of where the soft spots could be in your Order to Cash process. We invite you to take a few moments to fill out this form. A TGG consultant will contact you shortly to discuss your Problem Statement and provide some insight on how we may be able to help.

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