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01 · DefineCharter the problem
CharterControl chartCapabilityToolkitExecutive summary
Assignment · Charter
Reduce fill-line variation
ProblemLine 3 fill volumes drift ±4.2 mL across shifts.
Goal metricCut fill-weight σ by 50% (σ ≤ 1.05 mL) before the Q3 audit.
Business caseGiveaway and rework cost ≈ $310k/yr — halving variation recovers ≈ $182k.
SponsorMazan Nasser — Director of Ops
Process ownerJames Carter — Line 3 lead
In scopeLine 3 filler heads 1–8
Out of scopeUpstream mixing, packaging
● Saved · just now — every keystroke autosaves
Charter completeness72%
Toolkit · Control chart (I-MR)
Fill weight, last 40 lots
Values249.8, 251.2, 248.9, 250.4, 249.1, 252.6, 248.3, 250.9, 249.5, 251.8, 250.2, 249.7
Nelson rules run automatically — violations are flagged, never hidden.
Capability · Sixpack
Is the process capable?
LSL
246.0
Target
250.0
USL
254.0
LSL 246.0μ 249.8USL 254.0
Cpk
1.12
target ≥ 1.33
Sigma level
2.86σ
DPMO 41,300
Toolkit
34 tools, mapped to the right phase
Analyze
Pareto
3 runs · top cause 42%
Improve
DOE — 2⁴ factorial
speed × temp significant
Measure
Gauge R&R
%R&R 8.4 — acceptable
Analyze
Hypothesis test
Mann–Whitney · p = .0079
Control
Control plan
6 items · 2 owners
Define
CTQ tree
2 drivers · 5 CTQs
Control
SPC — EWMA
λ 0.2 · in control
Measure
Sample size
n = 34 per group
Define
Kano model
12 needs classified
Every run saves into the project — the report stitches all 34 together.
Executive summary
Reduce fill-line variation
Cut fill-weight sigma by 50% before the Q3 audit.
Sigma level
2.86σ → 4.1σ
DPMO
41.3k → 6.2k
Hard savings
$182k
Tollgates
5/5 approved
Top causes · Pareto & distribution
Nozzle wearTemp driftOperatorMaterialOther
LSLdistributionUSL
Process performance
Cpk0.80 → 1.37
Ppk0.76 → 1.31
Stability✓ In control
Recommendations3 implemented · RPN −62%
Charter brief
ProblemLine 3 fill volumes drift ±4.2 mL across shifts, driving giveaway and rework.
SponsorMazan Nasser — Director of Operations. Board-ready PDF in one click.
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