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WSC 2005 Final Abstracts |
Six Sigma and Simulation Track
Tuesday 8:30:00 AM 10:00:00 AM
Tutorial: Six Sigman and Simulation
Chair: Scott Bury (The Dow Chemical Company)
Simulation and Optimization as Effective Six
Sigma and Dfss Tools
Karl Lucie, Lucie Trepanier, Fred Ciochetto,
and Lawrence Goldman (Decisioneering, Inc.)
Abstract:
Simulation and optimization techniques can provide
Design for Six Sigma (DFSS) practitioners with reduced reliance on physical
prototypes, rapid time-to-market, minimal defects and post-design rework.
These advantages lead to quantifiable benefits within the product development
life-cycle, in terms of time and cost. Through one case study, this paper will
provide Six Sigma, Process Excellence and Lean practitioners with the
rationale for spreadsheet simulation and optimization in DFSS initiatives.
Discussion topics include the role of simulation and optimization in the DMADV
methodology, disadvantages of not quantifying uncertainty in DFSS projects,
differences between deterministic and stochastic optimization, and tradeoff
considerations when running optimizations. Practical techniques for
efficiently identifying robust, high quality solutions are demonstrated
through the use of Monte Carlo simulation and optimization.
Tuesday 10:30:00 AM 12:00:00 PM
Six Sigma and Simulation I
Chair: Martin Miller (Business Prototyping Inc)
The Use of Discrete Event Simulation in a Design
for Six Sigma Project
Michael J. Seifert (Capital One services,
Inc.)
Abstract:
This paper describes how a risk event to customer
satisfaction for a food service facility was identified, validated, and
eventually mitigated through the use of a discrete event simulation as part of
a Design for Six Sigma project. Further described is how simulation was
utilized to identify leading indicators to the risk event, to give pre-warning
of the occurrence as well as to perform what if tests to validate mitigation
practices and contingency plans. The results presented demonstrate how a
simulation model coupled with Six Sigma can design a superior process in
regards to predictability and reliability.
Evaluating Proposed Capital and Operational
Improvements at a Marine Terminal
Scott J. Bury and Naoko Akiya
(The Dow Chemical Company)
Abstract:
Marine terminal operations are complex, and evaluating
changes is best done using a simulation tool that captures the dynamics and
interactions of the system. We have developed a flexible and robust
discrete-event simulation of a marine terminal that handles liquid cargo. We
used this simulation to investigate proposed changes generated by a Six Sigma
project to reduce congestion at the terminal. Our study provided quantitative
data to base decisions on the expected operational and financial impact of the
proposed changes. The simulation captured the important details of the system
and increased the Six Sigma team’s confidence in their recommendations. The
modular architecture of the simulation allows for easy application of the
simulation to different terminal simply by changing a few data tables. The
structure of the simulation makes it easy for non-modelers to use the tool to
perform continuing studies.
Lean Sigma and Simulation, So What’s the
Correlation? v2
David M. Ferrin and Martin J. Miller (Business
Prototyping Inc) and David Muthler (PWC Consulting)
Abstract:
This paper will explore the fundamental relationships
between Lean Sigma and simulation. A basic overview of Lean Sigma includes: 1)
Lean Sigma philosophy, 2) Basic tools, 3) Theory of Variation, 4) SPC, 5)
Process capabil-ity,6) Lean Sigma infrastructure, and 7) DMAIC and DFSS
processes. Simulation will be applied to the appropriate areas of the
overview. Improvement in the robustness of the Lean Sigma methodology will be
discussed and the strengths of simulation will be presented as capable and
preferable enhancements to the Lean Sigma processes. Quotes from Lean Sigma
and industry leaders will be presented. Simulation will be presented as an
innovation tool enhancing the Lean Sigma DMAIC and DFSS processes.
Tuesday 1:30:00 PM 3:00:00 PM
Six Sigma and Simulation II
Chair: David Ferrin (Business Prototyping Inc)
The Application of Simulation Methodology in a
Hospital’s Six Sigma Project
Martin J. Miller (Business Prototyping
Inc.) and David M. Ferrin (Business Prototyping, Inc.)
Abstract:
Simulation was recently utilized as the key component
of a Six Sigma project at a major hospital in the southeastern United States.
The project team used various statistical analysis tools to assess current
process performance and measure improvements with process changes. However,
simulation provided the best insight into which process changes had the best
opportunity to succeed and which would yield little value. This paper briefly
discusses the methodology of this project and how simulation provided a better
quality solution.
Sensitivity Analysis for Robust Design
Experiments
Joseph R. Litko (University of Dayton)
Abstract:
Robust parameter design experiments lead to products
and processes that are insensitive to the effects of noise. These experiments
reveal the interaction of the noise sources with design or control factors
usually allowing creation of products that are relatively immune to noise.
Finding truly optimal settings for design factors depends on the noise in the
lab being representative of the actual operating environment and assumes
potential product users all see the same noise conditions. This paper shows
how basic design solutions can be shaped when multiple populations see
different noise conditions and when typical assumptions on noise sources are
violated.