Helicopter Exercises

In-house LEAN SIX SIGMA Learning Sessions

 All helicopter flights are manned by company pilots and a co-
pilot. Company pilots are licensed as required by government
regulatory bodies like the Civil Aviation Authority of the
Philippines. They also regularly undergo proficiency trainings
and competency exams to gauge their abilities.
 PROBLEM STATEMENT
The People of Marawi City and the soldiers
deployed in the area are waiting for more
than 1.5 seconds for the medical support and
the reinforcement to arrive, and the arrival
flight times were inconsistent and
unpredictable.
 Purpose:
The Marvel Incorporation has been incorporated to
provide helicopter to provide fast, reliable medical
and artillery support for the ground troops in Marawi
City using a helicopter with least flight variability and
longest flight time to eliminate the long intervals of
support and reinforcements.
Since the current helicopters that the SHIELD owns
cannot stabilize a least flight variability and longest
flight time, the team was assigned to develop a
helicopter that would fit the needs of the customer.
 Importance
The Executive Director of Shield, Col. Nick Fury
will not be wasting money and time in having
the medical and artillery support delivered.
Precision that the support needed will be
delivered within the specification of the
Executive Director.
To minimize the reinforcement time to less
than 1.5 seconds.
 Scope
From the time of phone call to the arrival of
reinforcement needed in Marawi City.
The team will be conducting a flight
simulation of helicopter with different
specifications.
Variables that are hypothesized to affect flight
time are Weight (weight of paper), Presence
of Stabilizers (paper clips), Length of Tail,
Length of wings and Type of Rotator Tabs
(Folded or Unfolded).
Schedule (Gantt Chart)
 Measures
Invalid
Invalid measurements are defined as simulated
helicopters that touched on any body part of the
pilot, touches or landed on the chair or
experienced extraneous condition during the
flight (door opening, air, etc.)
 Defect
Defects are simulated helicopters that have flight
time less than 1.5 seconds.
Reinforcement time is greater than the acceptable
threshold.
 Goals
Highest flight time and smallest standard
deviation.
Minimize the defect to 1.5 seconds.
 A stopwatch will be used to measure the time
flight of the helicopter made by the team.

Standard deviations will be computed using

the Minitab Application.
 Flight Time
Start Time The time that the paper helicopter
was released from the command center.
End Time The time that the paper helicopter
lands on the ground.
 Deliverables
The team is expected to produce the best
design of the helicopter that will be able to
deliver the medical and artillery support
needed.

To complete the project before June 28, 2017.

 Resources
The Executive Director of Shield, Col. Nick Fury
will be the one to provide all the resources
needed by the team to complete the project.
 Key Players
Team Leader Chief Consultant of the Aircraft
Members
Pilot
Simulator/Simulation Engineer
Statistician
Mechanic
Coach Sir Vic
Sponsor The President of the Republic of the
Philippines
Process Owner Col. Nick Fury
 Map the Process - SIPOC
SUPPLIER INPUT PROCESS OUTPUT CUSTOMERS

Step 1
- Ground troops call
for reinforcements

Step 2
- Main Base receive
and process request Supplies
Step 3 (artillery
Armored - Main Base assemble
Main Base requested team and and Soldiers
vehicles supplies.

Step 4 medical
- Deployment of
supplies support)
Step 5
-Arrival of supplies at
the ground troops
 Voice Of the Customer
Kano Model
Must Be needs that are expected by the customer
(e.g. airline safety, hotel check in, hospital admission)
More is Better needs that have linear effect on customer
needs (e.g. fast check in/hospital admission)
Delighters needs that do not cause dissatisfaction when
not present but satisfy the customer when present (e.g.
candies/cookies/coffee while waiting for admission)
 Voice Of the Customer
service

must be

more is better

delighter
PARETO
Critical To Quality Variables
Deployment Process Map
Translate the customer language into
Critical
to Quality (CTQs)
 measure
continous data vs discrete
mins of response (fabricate)
operational definition(start time and end time of
measurement)
 Measure
Sample Data Collections Forms
Checksheets are basic forms that help standardize data
collection by providing specific spaces where people should record
data.

Frequency Plot Checksheet a special type of checksheet used for

numerical data. It creates a picture that shows how often different
data values appear.

Concentration Diagrams a data collection form where you write

directly on a picture of an object form or work area.
 SAMPLE FREQUENCY PLOT CHECKSHEET

Data symbol
marked over
What is being appropriate
measured value; multiple
clearly points of same
labeled value are stacked

Numeric scale laid

out in equal
increments
 Measure
VARIATION
Process data shows how the
Variation Voice of the Process
process varies over time
65
60
55
50
45
40
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39

No two any things are exactly alike

Quantifying the amount of variation in a process is a critical step
towards improvement
Understanding what causes variation helps us decide what kinds of
actions are mostly likely to lead to lasting improvement
 Measure
Types of Variation
COMMON CAUSE
Inherent in any system
Common to all occasions and places
Degree of presence varies
Each cause contributes to small effect to the variation results
Variation will always give results that are in statistical control
Process is stable.

Common cause variation

50
40
30
20
10
0
1 3 5 7 9 11 13 15 17 19 21 23
 Measure
Reacting to Common Cause Variation

A process with only common causes is statistically

stable and in statistical control
In statistical control does not mean the results
are acceptable
Leaving the process is not an improvement.
Complete a DMAIC to improve the process.
A different approach is needed to improve a stable
system. Look at all data points to understand the
pattern.
 Measure
Lessons about Variation
Stable process
Cannot predict any given value
Data points will randomly fall within a given range
(control limits)
Control limits define the process capability

Unstable process
Data values may or may not fall within control limits
Pattern is not always random.

Goal: Minimize Variation!!!

 Measure
Matching Action to Type of Variation
TYPE OF ACTION

TYPE Special Cause Common Cause

OF
VARI Look for what Take action Study all the Make basic
ATIO was different based on the data changes to the
N between reported process
individual difference
points
Com Waste time
mon
Caus
Increase

variation

Gain better
understanding
of the system
Reduce
variation

e

Gain useful Reduce Lose time in Loss of

Spe
cial information variation responding to productivity,
the problem may increase
Cau
variation
 Measure

Tools for Understanding Variation

Time Plots (run charts)
Control Charts+control limit
Frequency Plots
pareto charts
Calculate Process Sigma Measure

Determine number of defect opportunity O=

Determine number of units processed N=

Determine total numbers of defects made D=

(include defects made and later fixed)
D
Calculate defects per opportunity DPO
NxO

Calculate yield Yield = (1 - DPO) x 100%

Look up in sigma in the process sigma table

Process Sigma =
 create a proces map
 BASIC FLOWCHART SYMBOLS
Terminator show the start and stop points in a process.
Terminator When used as a Start symbol, terminators depict a trigger
action that sets the process flow into motion.
Flow line connectors show the direction that the process
flows.
Process show a Process or action step. This is the most
Process
common symbol in both process flowcharts and process
maps.

Decision - indicates a question or branch in the process flow.

Decision
Typically, a Decision flowchart shape is used when there are
2 options (Yes/No, No/No-Go, etc.)

Connector this symbol is typically small and is used as a

connector to show a jump from one point in the process
flow to another. Connectors are usually labeled with capital
letters (A, B, AA) to show matching jump points.
Data
Data flowchart shape indicates inputs to and outputs from a
process.
Document
Document flowchart symbol is for a process step that
produces a document.
 Measure
WASTE: WAITING
Having to wait for another process to finish before you can
do your work

Examples:
Waiting for a decision
Waiting for a meeting to start
Waiting for the doctors to
start the procedure, etc.
 analyze
why
fishbone vs.causal tree
 verify cause an effect relationship-true cause
 statistic part