Question

Please answer the two questions with details

I will give a rating up

Question 1 (40 points) A black belt engineer started a new six sigma project to minimize errors and improve processes in an outpatient clinic in a local hospital. Develop a Failure Mode and Effect Analysis (FMEA) to define potential process or product risks. Use Microsoft Excel to construct a complete FMEA tool by A. Identifying two possible failure modes for patient experience in the clinic. [20 points] B. Calculate the corresponding Risk Priority Number (RPN). [8 points] C. Recommend an action plan for eliminating the corresponding failure modes and improving the process and product quality. [12 points) Question 2 (20 points) In metal cut to length machines, a big coil of steel sheets is cut into small metal sheets based on the lengths given by customer. The process starts by bringing a heavy steel coil from the warehouse by an overhead crane to the machine. Special trained operators install the coils for all the machines in the factory. Those operators are different than the regular operators who run the machine after installing the coils. The machine cut the metal coil using sharp knife. Installing new coil with different thickness requires changing the knifes set. Explain how SMED can be used to reduce the changeover time. (Use clear points)

Answer 1

1.

Ans:

Potential Failure Mode	Potential Failure Effects	SEV	Potential Causes	OCC	Current Control	DET	RPN	Actions Taken	SEV	OCC	DET	RPN
Patients wait long time for getting treatment	.- Customer satisfaction level getting down - Clinic impression is going down - Few patients suffering with pain during long waiting duration - Doctors are overburdened with work due to which they fails to prodive 100% service to the customers	5	.- Lack of appropriate number of doctors for providing the treatment	7	.- Doctors are pressurised to treat fastly	5	175	.- New doctors appointed after study the arrival rate and service rate of patients	5	3	5	75
Patients leave clinic due to lossing patience
Serious patients not getting immediate treatment just agter reaching at clinic	.- Some times patients dies due to delay in processes - Clinic impression going down	9	.- Poor communication medium - Improper trainning has given to the staff	2	.- After reach at the clinic the patients' condition ckecked and actions take	2	36	.- In case of arriving serious patients, the ambulance driver or others are trained to inform the patient condition to the clinic just 15-20 mins before reaching at clinic so that the hospital staff will make ready the equipments	9	1	1	9

2.

Answer:

SMED means single minute exchange of dies. It means reduce the setup time dramatically during changing of manufacturing from one product to another product. It has following steps to minimize the setup time:

1. Do the pilot study: It includes equipment selection, team member selection, and set the time for accomplishing the certain activity.

2. List all the activities: Do a video of the entire process and list all individual activities and the duration to accomplish it

3. Categorise the activities: The individual activities need to be categorise into two groups’ i.e external and internal activities.

4. Convert the internal to external activities: It is very much essential to reduce the external time in the production area. Because the value of external time is very high.

5. Systematically arrange the remaining activities.

In this way the setup time / change over time can be reducible up to great extent.