ROUND $3$ TOTAL CYCLE TIME PER UNIT WITH $2$ MACHINES

New number of machines MC$3($given$)$: MC$3=\_\_\_\_\_$

New total cycle time in minutes per unit:

$$TCT$\_3=($ST$\_2+$CT$\_1)/$MC$\_3$

TCT$3=\_\_\_\_\_$ MIN$/$UNIT

Your TCT$3$ is looking much better but could still use some improvement to meet customer demand. Your project team decides that better tooling will machine the widgets faster and reduce the cycle time $($CT$)$ per unit after setup. Switching to better tooling has reduced the CT to $0\mathrm{.}53$ minutes per unit $($CT$4).$ Calculate the new TCT$4$ based on the improved CT$4,2$ production machines, and the recently improved setup time ST$2.$

ROUND $4$ TOTAL CYCLE TIME PER UNIT WITH BETTER TOOLING

New cycle time per unit after setup CT$4($given$)$: CT$4=\_\_\_\_\_$ MIN$/$UNIT

New total cycle time in minutes per unit:

$$TCT$\_4=($ST$\_2+$CT$\_4)/$MC$\_3$

TCT$4=\_\_\_\_\_$ MIN$/$UNIT

$$

Your TCT$4$ is getting close to meeting customer demand. Your project team decides that defect reduction would be the best way to get the TCT under Takt time. You will do that by upgrading components on the production machines so there will be fewer machine failures that damage the widgets in process. Calculate the latest daily acceptable output DAO$4$ based on TCT$4.$ Right now the facility is producing DAO$4$ acceptable units$/$day $+200$ units with defects per day. Calculate the current total output $($TO$4)$ and current throughput yield $($TY$4)$ considering the defects.

ROUND $4$ THROUGHPUT YIELD

Daily acceptable output in units per day:

$$DAO$\_4=$PT$/$TCT$\_4$

DAO$4=\_\_\_\_\_$ UNITS$/$DAY

Total output:

$$TO$\_4=$DAO$\_4+$# Units with Defects

TO$4=\_\_\_\_\_$ UNITS$/$DAY

Throughput yield without defect reduction:

$$TY$\_4=$DAO$\_4/$TO$\_4$

TY$4=\_\_\_\_\_\%$

The defect reduction improvement results in a new throughput yield of $97\%($TY$5).$ Calculate the new daily acceptable output DAO$5$ based on TY$5$ and the existing total output TO$4.$ Then calculate the TCT$5$ based on DAO$5.$

ROUND $5$ TOTAL CYCLE TIME PER UNIT WITH DEFECT REDUCTION

New throughput yield TY$5($given$)$: TY$5=\_\_\_\_\_\%$

New daily acceptable output in units per day $($rearrange TY formula$)$:

$$DAO$\_5=$TY$\_5*$TO$\_4$

DAO$5=\_\_\_\_\_$ UNITS$/$DAY

New total cycle time in minutes per unit:

$$TCT$\_5=$PT$/$DAO$\_5$

TCT$5=\_\_\_\_\_$ MIN$/$UNIT

Congratulations! Your TCT is less than your Takt time, which means that you can now meet the customer demand of $1600$ units per day. Your initial calculations $($Round $1)$ and four rounds of improvements $($Rounds $2-5)$ including implementation of offline setup, adding another production machine, switching to better tooling, and reducing defects, have paid off.

$$

$97\%$ throughput yield is not bad, but how good is it in the grand scheme of things? Let$$s do some quality performance calculations to figure out where your organization$$s performance stands. Some of your units have more than one defect. As a result, there are $78$ defects total in one day. There are $3$ opportunities for a defect to occur in one unit, meaning the hole could be messed up$,$ the length could be wrong, and$/$or the width could be wrong. Calculate the following quality metrics below.

ROUND $5$ QUALITY PERFORMANCE

Number of defects DF $($given$)$: DF $=\_\_\_\_\_$

Number of opportunities per unit OP $($given$)$: OP $=\_\_\_\_\_$

Total output TO$4$: TO$4=\_\_\_\_\_$

Number of units with defects:

# Units with Defects$=$TO$\_4-$DAO$\_5$

# Units with Defects $=\_\_\_\_\_$

Average number of defects per unit $($uses total output rather than # units with defects$)$:

DPU$=$DF$/$TO$\_4$

DPU $=\_\_\_\_\_$

Parts $($defects$)$ per million units PPM:

PPM$=$DPU$*1,000,000$

PPM $=\_\_\_\_\_$

Defects per million opportunities DPMO:

DPMO$=($DF$*1,000,000)/($TO$\_4*$OP$)$

DPMO $=\_\_\_\_\_$

Sigma level $($use the table below to find the right sigma level based on your calculated DPMO$)$: Sigma Level $=\_\_\_\_\_$

DPMO SIGMA LEVEL

$308,5002\mathrm{.}0$

$158,7002\mathrm{.}5$

$66,8003\mathrm{.}0$

$22,7003\mathrm{.}5$

$6,2004\mathrm{.}0$

$1,3004\mathrm{.}5$

$2305\mathrm{.}0$

$305\mathrm{.}5$

$3\mathrm{.}46\mathrm{.}0$