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1. Six Sigma DMAIC Project
GEAE Account: Lynn MA Site
Project Leader/Green Belt: George Harris
Project Leader Title: Customer Engineer
Project Start Date: September 27, 2002
Master Black Belt: Steven Bonacorsi

2. Six Sigma in Action
Software: Special Applications
Customer Profile – 8,000 seat Aircraft Engines Manufacturing Company
Business Problem & Impact Process Capability – Before
GEAE shop floor end users experience unnecessary downtime during T USL
system replacement, due to incomplete configuration and uninstalled 15
required applications . One shop floor workstation can be down for days
as multiple help desk tickets are required to get the system 100% Sigma (ZST):
functional. 10 1.52
Frequency
Measure & Analyze Sigma (ZLT):
Data Collection: Cycle time to complete 1 shop floor deployment was 0.02
measured. Any deployment taking >60 minutes was listed as a defect 5
Root Causes: There is no process or documentation detailing the Shop
Floor Special Application Installation and Configuration
MSA Results: An MSA was not performed during Measure for the
0
following reasons: 1.Cost in labor to complete a measure MSA was to
great to complete. 2. GE ITS did not control the process used in baseline 50 100 150
3. Infrequent cases also made MSA too costly. Total Cycle Time
Improve & Control Process Capability – After
A Pugh Matrix was used to determine the best possible solution. Having T USL
GEITS technicians install special applications and configure shop floor 8
systems prior to deployment, had the greatest positive impact on cycle 7
Sigma (ZST):
time. 2.99
6
Sigma (ZLT):
Frequency
5
A new shop floor deployment process was developed and implemented
in March 2003, with training sessions and documentation provided to 4 1.49
deployment techs prior to rollout. All data points collected were within the 3
60 minute specification limit. 2
1
Results/Benefits
Mean cycle time decreased from >59 minutes to <33 minutes while 0
Sigma value increased from .02 to 2.99. This results in an expected 15 20 25 30 35 40 45 50 55 60
customer indirect savings >$7,600 (annually) Deploy Time
An ACFC Project with an Expected Customer of >$7,600 annually!