Project Definition Case Study #

BackgroundYour organization manufactures Time-of-Flight Laser Inspection Systems. These systems perform 3-dimensional scanning using laser light to probe an object. The laser range finder determines the distance of a surface by timing the round-trip duration of a pulse of light. This detects the distance in a specific direction of view at a point in time.To map the surface of an object, the laser scans the entire object by changing the direction of the laser beam through the use of a system of mirrors mounted on galvanometers.

This type of configuration allows the mirrors to be rotated very quickly and with great accuracy allowing up to 100,000 measurements per secondThese are complex assemblies that are assembled in-house from procured sub-assemblies. A listing of the major components and procured costs are provided in Table 1.The total time to assemble and test the final unit is about 50 hours and is at a cost of $3000.The selling price of a completed system is $25000.For some time, customers have been complaining about a high rate of failure of recently installed systems and this is impacting profitability and customer satisfaction. This dissatisfaction was first noted about 12 to 18 months ago and is now at a level where problems need to be addressed.

Using some or all of the following information, define a LSS project.

Process Flow -The basic process flow is very simple. Subassemblies are procured from subcontractors and held in stock. They are released to the floor in batches for production assemblies. Subassemblies are mounted to a chassis, wired up, the galvanometers and lasers are aligned and a simple functional test is performed.

Once the technician is satisfied with the functional performance. The unit is closed and a final test process is performed.On completion of final test, the unit is packaged and shipped to customers for installation. Field installers report problems via an incident report.Once commissioned the systems remain under warranty for one year. If a problem is experienced, the customer can return the unit for repair or replacement.

If a customer identifies an issue which requires that the equipment be returned, he informs the manufacturer and is issued with a Return Material Approval (RMA). The equipment is then returned and a troubleshooting exercise is conducted. On completion of troubleshooting, the unit is repaired as necessary and is either returned to the customer or goes into a replacement pool. There are currently 30 systems in the pool.

Available Data

Final inspection data is available in Table 2. Data covers the last 12 months of manufacturing.

Table 3 is a summary of install issues for October. Assume that it is representative of any month.

Table 4 provides summary troubleshooting and repair analysis for the month of October, again assume that it is representative of any month.

The labour rate is $60/hour.

Part Type	Procured Cost
Laser Module	$3000
Galvanometer Assembly (per pair)	$4000
Power Unit	$1500
Control Board	$750

Table 1

Month	Nov	Dec	Jan	Feb	Mar	Apr	May	Jun	Jul	Aug	Sep	Oct
Built	100	50	50	100	100	50	100	50	100	50	100	100
Fail	1	0	1	1	2	1	2	1	2	0	1	1

Table 2

Issue	Number of incidents
Laser output low (adjusted on-site)	2
No output	1
Retuned Galvanometers (adjusted on-site)	4
Other	1

Table 3

Time since install	Issue	Repair action	Total time taken
Less than 1 month	X-Axis galvanometer out of calibration	Retuned X-galvanometer	10 hours
	Y-Axis Galvanometer not functioning	Replace galvanometer and re-test	20 hours
	No laser output	Replace control board	5 hours
1 to 3 months	Both Galvanometers out of calibration	Replace Galvanometers and retest	25 hours
	X-Axis galvanometer out of calibration	Retuned X-galvanometer	10 hours
	X-Axis galvanometer out of calibration	Retuned X-galvanometer	10 hours
	X-Axis galvanometer out of calibration	Retuned X-galvanometer	10 hours
	Low laser output power	Retuned control circuit	5 hours
	Power supply short circuit	Replaced PSU	10 hours
	Y-axis Galvanometer failure	Replace galvanometer and re-test	20 hours
	X-Axis galvanometer out of calibration	Retuned X-galvanometer	10 hours
3-6 months	Galvanometer out of calibration	Retuned control circuit and replaced galvanometer	15 hours
	No output power	Replaced laser	10
	No output power	Replaced laser	10
	No output power	Replaced laser	10
	No output power	Replaced faulty control circuit	15
	Galvanometer out of calibration	Retuned galvanometer	10
	Galvanometer out of calibration	Retuned galvanometer	10
	Galvanometer out of calibration	Retuned galvanometer	10
6-12 months	No output power	Replaced laser	10
	No output power	Replaced faulty control circuit	15
	Galvanometer out of calibration	Retuned galvanometer	10
	Galvanometer out of calibration	Retuned galvanometer	10
	Galvanometer out of calibration	Retuned galvanometer	10

Table 4

Using some or all of the ABOVE information, define a LSS project.

1)PROCESS FLOW CHART

2)PROJECT CHARTER

Problem Statement

The Problem Statement should address these questions: What is wrong, not working and not meeting our customers needs? When and where do the problems occur? What is the frequency of the problem? Whats the impact of the problem on our customers/business or employees? What is the financial impact of the project and/or problem

Business Case & Benefits

The Business Case should address these questions: Why is this project worth doing? Why is it important to do now? What are the consequences of not doing this project? How does it fit in with business initiatives and targets?

Goal Statement

[increase/Decrease] [Unit] from a baseline of [baseline] to a target of [goal level] by [date projected to reach target level]

Scope - First/Last and In/Out
1st Process Step
Last Process Step
In Scope:
Out of Scope: