BSc Quality Project: Streamlining Production at Dell EMC, Navan

This project outlines the process improvement initiatives undertaken at Dell EMC to streamline the mass production of electronics devices. The project identifies key problems such as lack of clear instruction, excess stocking of goods, and errors during assembly and testing. Using the Lean Six Sigma roadmap, the project defines the problems, measures the existing processes, analyzes the root causes of variations like excess communication and defective products, and implements improvements such as proper communication techniques and a build-to-order system. The new process aims to reduce processing time, minimize errors, and improve customer service. The project also includes a value stream mapping to compare the old and new systems, highlighting the time savings and process improvements achieved through the implementation of new communication techniques and optimized testing processes. The document is available on Desklib, a platform offering a wide array of study tools and solved assignments for students.

DELL EMC
Improvement
process

The Team
 Project Sponsor
 Project Leader
 Team Members

Using Lean 6Sigma
Roadmap
Measurement of the
processes
Identify the
problem
Implement
Improvements
Analysis of the
process
Sustain benefits

DEFINE
Provides the customer with better service and
products
Effect on
costumers?
Lack of
clear
instruction
Excess
stocking of
goods
Errors
during
assembly
and test
What problem have we encountered?
Several steps are unnecessary involved in the
production
What is not working?
Opportunity to improve?
Elimination of various steps involved in manufacturing
Proper communication system
Shutting down of units which fails during the test
process
Reduction in the stocking of goods and built to order
system
Minimization of the wastes
Identify the problem

MEASURE
How many units return to
rework or retest
Time required for
processing
Space of storage area
Collect Data

08/28/2
024 6
Gap analysis- Reason for poor performance
MEASURE
Poor performance
Lack of clear instruction
Excess Communication
Excess work
Failure in tests
Mistakes in work

Excess
communication
• Due to excess amount of
communication between
the technicians and the
software engineers
Mistakes of the
people
• Due to excess
communication
• Failure in the tests
Failure of products
• Defective products
• Manufacturing errors
Excess stocking of
the goods
• Production of good only
according to the order
MEASURE
Gap Analysis – Root cause of variation

Using 5 most commonly ordered sizes – including largest and smallest
sizes
Excess
communication
Proper
communicati
on
techiniques
Move to
Excess
stocking of
the good
Build to
Order
system
Move to
MEASURE
Determine of new
process

Proper
communicati
on technique
Unorganised
way of
communicati
on
Replaces
Build-to-
order
system
Excess
stocking of
the goods
Replaces
Various types
of tests
The unnecessary
steps involved in
the production
process
Replaces
MEASURE
Determine new process

Configuration
according to
the order
Final testing
process
Improved
process
Managing the
communicati
on system
MEASURE
Control

11
Project Objective’s
Assembly
Assembly
Verification
Test
Basic
Configuration
Test
Configure
To
Order
Final
Test
6 hours/unit 10 hours 1 hour4 hours 5 hours
Customer
New Value Stream Mapping
Assembly
Assembly
Verification
Test
Basic
Configuration
Test
Configure
To
Order
Final
Test
6 hours/unit 10 hours 1 hour4 hours 5 hours
Customer

Replacing the old system with the new system is time consuming
Few processes needs to be shut down for the purpose of implementing new
processes
New communication techniques are to be adopted
The current processes needs to be analysed and tested
properly
Comments
Suggestions