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 LEAN SIX SIGMA WORLD CONFERENCE

DMAIC at Armstrong- Results That Will Floor You!

Presenter:  David Hanan, 6 Sigma Development Manager, MANTEC, Inc., Chambersburg, PA, USA
Co-PresenterSydney Tefft, Operations Leader, Armstrong Flooring Inc., Lancaster, PA, USA

Keywords: 6 Sigma, DOE

Industry: Manufacturing

Level: Intermediate

ABSTRACT

Armstrong Flooring, with over 150 years of experience, is North America’s largest producer of resilient residential and commercial flooring products, with manufacturing plants in 5 states and Australia and China. Operational Excellence is alive and well at Armstrong as Green and Black Belts focus on yield and product cost reduction using DMAIC. An example of recent project success focused on improving yield on the commercial tile product line. Commercial Tile was selected following a Pareto analysis which identified products and associated defect types.

Defects including field issues were examined insuring Voice of the external Customer was included in the problem statement. A measurement system analysis (MSA) uncovered opportunities to improve the repeatability and reproducibility for a main defect measurement. The team used a number of qualitative tools, such as the SIPOC, Cause and Effect Matrix and weighted decision making to narrow down potential sources of variation and factors for a designed experiment. After several prove/disprove t-tests on hypothesized causes, the problem area was identified and a split plot DOE was utilized to examine the critical response and factors. Finally, Response Surface Modelling was employed determining process settings based on model interactions. Armstrong has shared these important findings multiplying the impact of this study to other facilities, similar products, and emphasizing scientific problem solving. The results: a clean sweep increasing yields and improving productivity.

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