1. C170 Ignition Cylinder Name: Key Chime alarm stays on when key removed
Organization: Huf North America
Project Location: Wayne Assembly
Global 6-Panel Reporting standard:
6-Panel Problem Resolution is a high level problem resolution document to capture the key requirements and data to drive decisions through the problem solving phases: Define, Measure, Analyze, Improve, Control, and Replicate.
Assist problem solving teams with a template to guide the problem solving process using minimum required DMAIC+R steps to ensure robustness of the resolution.
Individual summary panels of each DMAIC+R phase that is simplified and standardized, while allowing for additional information or slides to be inserted as backup information for any of the problem resolution phases. In a high level management report out, communicate with the six summary panels. For a team or quarterback deep dive, unhide information on additional slides.
Standardization of problem resolution procedures combining best practices and 6-Sigma methodology on a format that is flexible enough to be used by all business units.
Simplified and consistent communication to management in a concise way without having to rewrite what you have done.
Encourages management to ask questions in line with the 6-Sigma disciplined methodology.
Follow the instructions on the notes pages for minimum slide content for each of the phases. If you need additional slides, insert new slides to provide additional information to support details for a specific phase. Ensure your slides are readable and tell your story. Courses are available, for example: “Ford Power Presentations” is available through FTDC.

2. DEFINE VOICE OF THE CUSTOMERA I C R
DEFINE VOICE OF THE CUSTOMER
PROJECT CLASSIFICATION:
Incoming quality
TREND CHARTS and BREAKDOWN OF ISSUE:
VOICE OF THE CUSTOMER: The key chime must not sound when the key is removed and the door is open.
CTQ STATEMENT (Customer Requirement): Ignition lock cylinder returns upon key removal, keychime is deactivated, steering column locks.
DEFECT DEFINITION for Y (Engineering Metric):  A small burr on a cam in the ignition cylinder prevents the assembly from shuttling back after key extraction far enough to both deactivate the key chime switch and allow the steering column lock driver to clear the lock bolt.. This causes the key chime to remain activated and the steering column not to lock. The presence of this burr was not identified as a potential failure mode during DV and PV testing.
COST OF POOR QUALITY: 
PROBLEM STATEMENT, SCOPE, AND GOAL : The problem is that the key chime can intermittently stay on after the key is removed for vehicles produced at WSAP, OHAP, KCAP, and Hermosillo. The goal is to eliminate this intermittent condition on all units.
Y=f(x) CASCADE:
DEFINE PANEL (Minimum requirements):
Identify VRT to CCC cascade of the issue in the header.
Identify the Project Classification (Safety, Quality, Deliver, Cost… objectives: see SAQ=Single Agenda for Quality example above)
Trend Charts and Breakdown of Issue (Internal or External trends, and graphical quantification and pareto to help break down the issue.
Y=f(x) Cascade (High level Y=f(x) cascade should communicate the scope of the project).
CTQ (Critical to Quality) Statement - identifies customer need.
Defect Definition of Key Process Output Variable (KPOV or Y) in the form of an engineering metric.
Cost of Poor Quality (Cost of the Problem includes all external and internal cost, TGW, Unexpended Warranty, labor & overhead, etc.)
Problem Statement (include scope and goal)
Additional Tools: (add slide(s) to capture backup Define material)
Process Mapping (As Is), SIPOC, Is-Is Not Analysis
Unexpended Warranty Calculations
TGW Verbatim Analysis
QFD
Please note: The header “VRT / VFG / CCC” information along with the footer “Project Number / BB Name” information must be updated on the SLIDE MASTER. Goto “View” then “Master” then “Slide Master” to make these changes.

3. MEASURE CTQ (y) CAPABILITYD M A I C R
MEASURE CTQ (y) CAPABILITY
Cause & Effect Diagram w/ Ranking:
MSA & Process Capability:
Engineering Test Requirement test name spec
MEASURE PANEL (Minimum requirements):
Identify the key process input variables (KPIV or Xs) that affect your KPOV (Y) most. Display Ranking.
Validate the Measurement System for your KPOV (Y). (Gage R&R stated as % Study) (May be needed for both Ys and Xs performed in other stages of the project.)
Determine the Baseline Process Capability of your KPOV (Y)
Containment - state actions taken to protect the customer, including statistical evidence validating action (before and after data). If containment is not needed, state why. (Containment can be stated in the Analyze phase, if appropriate.)
Additional Tools: (add slide(s) to capture backup Measure material)
Cause & Effect Matrix
P-Diagram
PFMEA and/or DFMEA
SPC
Rolled Throughput Yield
Process Elements Element OK A Investigating B Element Not Capable C Element Removed D
CONTAINMENT (state reasoning if not required): Process Owner Date Before Data After Data
Sort current stock visually to remove cylinder cams with burrs S. Stacy 4/27/ R/ R/1000
Cams certified under magnification for no flash in ejector pin area J. Kilday 5/18/ R/ R/1000
Revise ejector pins and Block off cavities #3, 4, 7 and 8 of the cam
tool to eliminate primary source of burrs Supplier 5/20/ R/ R/1000

4. Analysis of parts from WSAP:D M A I C R
ANALYZE y=f(x)
Analysis of parts from WSAP:
ANALYZE PANEL (Minimum requirements):
Which Inputs (Xs) affect my Outputs most (with data)?
How many samples do you need to draw conclusions?
What level of confidence do you have in your conclusions?
Additional Tools: (add slide(s) to capture backup Analyze material)
Graphical Analysis & Hypothesis Testing
Regression Analysis
Correlation Analysis
Process FMEA
P-Diagram
Contribution Analysis
Multi-vari studies
Shainin Analysis

5. Technical Corrective Action:D M A I C R
IMPROVE y=f(x)
Technical Corrective Action:
Complete tool to eliminate possibility of burrs at current revision level. Parts available 6/3/04. Plant trial run 6/15/04.
Redesign cam with improved geometry to increase robustness of function. First parts available 8/2/04. Pending completion of testing and all plant approvals, the planned implementation date is 9/28/04.
Systemic Corrective Action:
Electronic test for cylinder shuttle with lockout added to end of line check to simulate audible sound of key chime switch in vehicle. 5/6/04.
The print for this part and the DFMEA have been modified to clearly identify the critical nature of the surface of the cam in this area.
Control Plan and PFMEA updated to reflect failure mode
Supplier control plan and Huf Incoming Inspection plans modified to include this condition and AQL has been increased to aid in detecting condition.
IMPROVE PANEL (Minimum requirements):
What is the optimal Y=f(x) solution?
How was optimal solution verified? (Statistical proof that the solution works.)
Key actions taken and work plan to improve. (Work plan must include: a) Permanent/Interim actions, b) Sample size, c) Next steps if trial is successful, d) Next steps if trial is NOT successful, e) Part availability if trial is successful, f) Additional actions pending.)
Validation of fix after implementation. (Before and after process capability of Y, showing variable data histograms, attribute data, etc.)
Additional Tools: (add slide(s) to capture backup Improve material)
Design of Experiments (Main Effect & Interaction Plots, ANOVA Tables)
Regression Analysis
Correlation Analysis
Hypothesis Testing
Cost / Benefit Analysis
Process Mapping (should be)

6. REPLICATION (who else across Ford Motor Company could benefit?):
REPLICATE
REPLICATION (who else across Ford Motor Company could benefit?):
Same ignition is used in HSAP and a similar ignition for U204 in OHAP and KCAP using the cam from same tooling used at KCAP and OHAP. A similar ignition will be used for 2005 MY EN/FN at Wixom and St. Thomas assembly plants starting later this year.
UPDATES TO CORPORATE KNOWLEDGE BASE (who else across Ford Motor Company could benefit?): Core Book Change Made Owner Document # Completed
Attribute FMEA
Design FMEA Failure Mode added Herre D L 5/26/04.
Process FMEA Failure Mode added Vargas 5/26/04
REPLICATION PANEL (Minimum requirements):
Who else at Ford could be affected or could benefit? (Replication at another Plant or on another vehicle line?)
Are there any larger business unit or even global intellectual capital effects? (SDS, FMEAs, VDS, etc. in need of updates?)
After 6 months, is the process still in control and the improvement in Y and X sustained? (Control Charts, Proof from Warranty or GQRS, etc.)
Additional Tools: (add slide(s) to capture backup Replicate/End material)
SPC, Control Charting
PROJECT END – PROOF OF SUSTAINMENT:
On-going