I need project expample on downtime reduction in machines using six sigma methodology. Anyone can share?

Answer 1

A six-sigma approach would be to monitor downtime as a percentage of total time, and to develop an understanding of "capability" (the machine is "up" 78% of the time, with a 90% confidence level). This establishes an objective (not subjective) basis of performance.

A failure tree or fault analysis is performed (what are all the possible causes of "downtime"?) and a Pareto analysis is done on these causes (80% of downtime is caused by people unplugging the machine, 10% is caused by broken tooling, 3% is caused by plant power failure...).

Then actions are planned and performed to address the downtime, including financial analysis (we need to train people not to unplug the machine, this will cost $5, but will save $20, etc.)

Then, the most financially sound actions are implemented and the original study is performed again.

Six sigma has to do with measured capability, and that an operation is most efficient when it operates within its capability. Objective measurement is required to determine capability. If the capability is inadequate to meet requirements, investment to modify the capability to the better, or a re-negotiation of requirements are required to match capabilities to requirements.