Canadian Operational Research Society

Calgary Section

http://www.corscalgary.org/

PROFESSIONAL DEVELOPMENT SEMINAR

When: Noon to 1:30 PM, Friday, October 21, 2005

Room 217

TransCanada Tower

450 - 1 Street SW

(See attached map)

SPEAKER

Sara Haynes, P.Eng., CQE

Process Consultant

Sigma Solutions

Calgary, Alberta

TOPIC

Productivity improvement for a manufacturing process: the black belt attack

Abstract

The Six Sigma approach to reducing defects is presented, using the polymer extrusion process for a major chemical company as a case study. In the space of 6 months, the project created $490 000 US in cost savings by increasing product yield. The case study showcases the DMAIC (Define, Measure, Analyze, Improve, and Control) technique of solving complicated manufacturing problems. The root causes of the polymer extrusion yield problem are identified using traditional Six Sigma methods. Data is the backbone of the project, used to monitor and evaluate progress. Several statistical analysis tools are used to solve the yield problems, including a design of experiment (DOE). Methods of permanently sustaining the yield increase are presented.

About the Speaker

SARA HAYNES is a chemical engineer with 7 years experience in creating breakthrough performance improvements in manufacturing processes. Sara began her career at DuPont Canada in Kingston, ON as a process engineer. Shortly after, she began immersed in the ways of “Six Sigma” - a new quality program that was revolutionizing companies such as GE, Allied Signal and Motorola, cutting costs and dramatically improving profit margins without the need for capital expenditure. After several black belt projects, one of which earned her a DuPont Award of Business Excellence, she continued her career with an alternative energy company in Calgary called Global Thermoelectric (now VersaPower). She has recently launched a consulting business, providing her expertise on process improvement to both healthcare and manufacturing organizations.

Sara is a member of APEGGA, ASQ, APICS, CORS and a graduate of Queen’s University, Kingston ON. She is an active volunteer with the Canadian Cancer Society, ASQ and APEGGA.