DMAIC Project Manager
3 active projects · AI monitoring · Auto-populated from facility data
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Line 2 Die Scrap Reduction
Production · Die clearance deviation at station 4 · $38,400/mo material loss
ANALYZET. Johnson · S. Reyes
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Ford PPM Reduction — Door Brackets
Quality · Ford Wayne Assembly defects · PPM 142 vs target 50
DEFINES. Reyes · D. Clarke
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Line 1 Changeover Reduction (SMED)
Production · Changeover at 47 min avg · Target 28 min
CONTROLT. Johnson · L. Park
Line 2 Die Scrap Reduction
DMAIC Project · Production · Owner: Terrell Johnson + Sandra Reyes
DEFINE100%
MEASURE100%
ANALYZE65%
IMPROVE0%
CONTROL0%
PLANTPILOT AI · ANALYZE PHASE SUMMARY
Root cause confirmed: die clearance deviation at station 4 producing tear-out and burring on the body-side bracket. Regression analysis (R²=0.78) shows clearance deviation as primary driver (62% scrap contribution). Contributing: worn punch tip geometry on Tool ID AP-204 (18%). Maintenance logs confirm Tool AP-204 ran 118,000 hits past scheduled PM due to SAP migration data loss. Corrective path: die insert replacement + tooling PM SOP update. Recommend transitioning to Improve phase immediately. Estimated savings post-fix: $34,200–$38,400/month.
✓ Define Phase
✓
Project charter written — scope: Line 2 scrap ≥1.5%
T. Johnson
✓
SIPOC completed, process mapped
L. Park
✓
Baseline scrap cost quantified: $38,400/mo
S. Reyes
✓ Measure Phase
✓
MSA completed — Gauge R&R ≤10%
D. Clarke
✓
30-day defect data collected by station
S. Reyes
✓
Cpk baseline: 0.83 — incapable process
S. Reyes
▶ Analyze Phase
✓
Fishbone + 5-Why completed for station 4
L. Park
✓
Regression: clearance deviation R²=0.78
S. Reyes
▶
Hypothesis test on tool AP-204 geometry
In progress — D. Clarke
Root cause report for leadership sign-off
T. Johnson
○ Improve Phase
Die insert replacement — Tool AP-204
R. Dolan
Updated SOP-PRD-022 Rev 2.2 issued
L. Park
Pilot run: 10,000 parts — measure scrap
T. Johnson
Document Generator
Line 2 Die Scrap Reduction · All DMAIC data auto-populated · One-click generation
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Project Charter
DMAIC Scope · PDF
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Tollgate Report
Analyze Phase · PPT
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8D Report
Ford-format · DOCX
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Control Plan
IATF 16949 · XLSX