The maintenance of products such as aircraft engines is part of a complex supply

Question

The maintenance of products such as aircraft engines is part of a complex supply chain. Distribution centers fulfill orders for spare parts to customers around the world and typically run on a 24/7 basis. Each day, as many as 4,000 different SKUs are shipped out and more than 1,000 SKUs are received in inventory. It is critical that each order be 100% accurate. For example, orders that don't match the shipping list are returned to the distribution center because of customs regulations. a. If the distribution center has identified inaccurate shipments as a sig- nificant problem, explain how the DMAIC process might be applied. shipment." process map (You may want to refer to process measurement concepts irn b. Develop a logical cause-and-effect diagram for the problem "inaccurate c. Think about how a process for fulfilling orders might work and create a

Explanation / Answer

Part a DMAIC stands for Define . Measure , analyse , Implement and Control

Define - inaccurate shipments of aircraft engine spare parts (Problem is defined)

Measure - Inaccurate shipment rate of 5 inaccurate shipments per 100 shipments ( Problem is measured at the current level by using past data)

Analyse - Use of various tools such as fish bone diagram , FMEA etc to arrive at the root cause ( Heart of DMAIC - high amount of brainstorming on each and every process and subprocess associated with shipment ordering,

Implement - Implementation of measures to eradicate root cause....... It is the result or outcome of Analyze step that guides this step

Control - Regular checks and inspections to ensure that the root causes are addressed. All the implemented measures are tried to made sustainable and make sure that process violations are not there

b) CAUSE AND EFFECT DIAGRAM
Problem - Inadequate shipment

MAN- 1. error while taking order, 2. Error when selecting spare part for dispatch 3. error when checking with order receipt 4. error while packaging 5. error in sending to wrong address 6. Lack of training 7. lavk of sleep 8. lack of motivation

Machine - 1. wrong SKU code in database 2. Poor quality equipments 3. Lack of regular maintenance

Method - 1. Taking orders over a phone on a noisy area 2. NO Double checking at each stage 3. Lack of common procedure 4. Poor communication 5. Interfering with others work

Material - 1. Same sized product but of different company / material 2. Lack of modern inventory software

Measurement - 1. poor measurement knowledge of workers 2. Faulty measurements

Part C The process for fulfilling orders is defined below using stages

Stage 1 - Receipt of order

Stage 2- Checking the required quantity with current inventory - if sufficient fulfill order if not , then order inventory and then fulfil the order

stage 3 - The order is sent to workers to take out all necessary inventory items per order

stage 4 - the items are checked for quality and packed

stage 5 - The final inspection done and the worker matches inventory in shipment box with order and seals it

stage 6 - shipment of the order

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