FINANCE DEPARTMENT PROJECT BACKROOM Sony Six Sigma Champion
FINANCE DEPARTMENT PROJECT: BACKROOM Sony Six Sigma Champion: Marcelo Freitas Black Belt: Joao Franco Green Belt: Mauro Perin and Andre Belleza 1
DEFINE PHASE Sony Six Sigma Ver. 2. 4
Customer Diagram Date: 02/SEP/03 Company/Plant COSTS OPTIMIZATION AND CONTROL HOME OFFICE COLUMBIA TRISTAR Department/Title FINANCE & ADMINISTRATIVE DIRECTOR Name MARCELO FREITAS 3
Define Diagram 2. Commitment to Your Process Department FINANCE DIRECTOR Name MARCELO FREITAS Date 02/SEP/ 03 Commitment (in plain language understandable to the customer) REDUCTION IN 30% OF THE FREIGHT AND BACKROOM COSTS BY THE END OF THE FY 04 (FEBRUARY/04) 1. Customer and VOC Customer HOME OFFICE Customer Requirements with Voice FREIGHT COSTS REDUCTION BACKROOM COSTS REDUCTION Basic Requirements without Voice CASH FLOW IMPROVEMENTS COMPLIANCE WITH LEGAL REQUIREMENTS Subconscious Expectation ELIMINATE AUDIT ISSUES VOC FREIGHT AND BACKROOM COSTS REDUCTION IN 30% 4
CE Diagram Department: Finance Director, Columbia Tristar Name: Marcelo Freitas Date: 02/SEP/03 Promote economy of scale Create Prints Destruction Policy Achieve Freight single supplier. Present Freight & Backroom cost until Sep/03 was R$ 1, 8 million Optimize Backroom Cost Destroy used Prints Customer Home Office VOC TRANSPORTATION & STORAGE COSTS REDUCTION Commitment REDUCTION IN 30% OF THE FREIGHT AND BACKROOM COST. Improve Skills Train Personnel 5
CTQ Diagram - A Department: Name: What FINANCE DIRECTOR, COLUMBIA TRISTAR M. FREITAS Date: 02/SEP/03 To What Extent When to achieve Person In Charge CTQ 1 Achieve Freight Single Supplier 100% End of FY 04 Franco CTQ 2 Optimize Backroom Cost 30% End of FY 04 Franco CTQ 3 Destroy Used Prints 70% End of FY 04 A. Sala CTQ 4 Improve Skills 100% of Personnel End of FY 04 A. Sala CTQ 5 CTQ 6 CTQ 7 CTQ 8 6
BACKROOM EXPENSE (R$ 000) *Data collected until August 7
BACKROOM LOCATION 8
PRINT UNITS DELIVERED (2002) 9
Tree Diagram Improvement Target: Optimize Backroom Cost Reduce in 30% the Backroom cost in SP Reduce 30% Backroom cost OTHER STATES 10
MEASURE PHASE Sony Six Sigma Ver. 2. 4
Process Flow Diagram Start Labs duplicate Prints and send to the Backrooms Transport Co. A Murundu informs Sales about the Prints. SDF informs Sales about the Prints. Sales instructs Backroom to send the Print to the Theatres Transport Co. B Transport Co. C Transport Co. D Transport Co. E Transport Co. F THEATRES 12
INVOICE BREAKDOWN Department: Finance Director, Columbia Tristar Name: Marcelo Freitas Date: 14 /OCT /03 13
INVOICE BREAKDOWN 14
Tree Diagram Metric Improvement Target Optimize Backroom Cost Reduce in 30% the Backroom cost in SP Reduce Storage cost of Films. OTHER STATES Other Costs on the invoice Percentage of Storage Cost on the Invoice Reduce 30% Backroom cost 15
Project Purchase Order Sheet (PPO) Dept. : FINANCE CH Name: MARCELO FREITAS Date: 14 /OCT/03 BB Name: FRANCO STEP-2/14 STEP-3/14 CTQ Project Name What to achieve Optimize Backroom Costs To what extent BACKROOM Improvement Metrics Percentage of Storage Cost on Invoice STEP-5/14 Current Values 24% of Total Invoice relates to Storage Cost. 30% When to achieve End of FY 04 (February/04) STEP-5/14 CH Approval Date 02 CH Signature STEP-5/14 Marcelo Freitas STEP-5/14 PGS Schedule 02/09/03 Measure 14/10/03 Analyze 14/11/03 -) Improve 14/12/03 PGS Control 14/01/04 R$ 300 K annual Investment: Target Values Reduce from 24% to 17% the Storage Cost STEP-5/14 Define Gains+Savings: /SEP/03 Project Members GB Mauro Perin Andre Belleza 16
ANALYSE PHASE Sony Six Sigma Ver. 2. 4
CE Diagram Department: Finance, Columbia Tristar Name: Mauro Perin Date: 14/OCT/03 18
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