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(Describe your answers in diagrams where necessary)
Please read the following Business Case in a Six Sigma project

You are assigned as New Product Development (NPD) Manager in a local electronic company. The company develops smart and innovative products for international markets. Your new assignment is to develop an innovative product to assist factory owners to manage their factories more efficiently by using the latest technology. This product is called e-Safety.

The main objective of the product is to reduce accidents at workplace since roughly 240 accidents was reported last year. The product is targeted to reduce accidents at least 20%. It allows the factory owners to manage their factory floor and electrical appliances remotely, monitor the security of the factory using CCTV. e-Safety also alerts the owner when there is any faulty in the factory floor, electrical appliances, fire, flood and intrusions or break-ins. Furthermore, it allows communications using 3G, 4G or Internet facilities. e-Safety also has GPS system with more value-added features such as panic buttons which will alert the nearest police station in an emergency such as robbery.

e-Safety is a micro-processor based system with a touch-screen LED interface, hand-held and uses rechargeable battery. The device uses a 3G/4G SIM card (for sending SMS and checking status). e-Safety also supports both 110V/220V users, supports multi-lingual and will be exported to all over the world. Furthermore, it is easy-to-use, user-friendly, maintenance-free and supports file transfer (Daily/ Weekly/Monthly Reports) through USB port.

The top management has assigned you to develop this product using Six Sigma methodology (DMADV) within 6 months from design to final product. Each phase (in DMADV) should not take more than 30 days except Develop Phase (60 days).

Based on the above business case:
a. Develop a Team Charter (TC) [5 marks]
b. Develop the Voice of Customer (VOC)
[10 marks]
c. Develop a Kano Analysis
[10 marks]
d. Develop a FMEA [5 marks]

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Table 1 shows a sample data for industrial accidents (male and female) and staff attended safety training in a manufacturing plant. There are 200 male and 200 female staff working in this plant. The main objective of this study is to find out whether there are any direct relationships between number of industrial accidents (male and female) in workplace and number of staff attended safety training in a particular year.

a. Use the data in Table 1 to plot regression (linear and quadratic) graphs for both male and female staff.
[8 marks]

b. Calculate the p-value for both data set and their data distribution type.
[4 marks]

c. Calculate R2 and standard deviation value for both equations.
[4 marks]

d. Briefly explain the most suitable equation to represent the regressions.
[4 marks]

e. What are three key conclusions from this study?
[6 marks]

f. What is the number of accidents if 80 staff (male/female) attended training?
[4 marks]


Staff Attended Training (Male) Accidents (Male) Staff Attended Training (Female) Accidents (Female)
10 27 10 22
15 25 15 21
20 23 20 20
25 22 25 18
30 20 30 17
35 19 35 15
40 18 40 16
45 18 45 16
50 17 50 14
60 15 60 12
70 13 70 10
75 12 75 9
85 10 85 8
90 8 90 7
95 7 95 7

Table 1: Number of Accidents vs Training Attended in 2014




You are the Safety and Quality Manager in a local company producing industrial safety products. Your boss just attended a Six Sigma awareness course for Senior Managers. He is very interested in Six Sigma methodology after attending the course and decides to implement it across the organisation. However, he needs to write a Board Paper to get approval from the Board of Directors before implementing Six Sigma. Your boss requests that you provide input to the following areas

i. How Six Sigma can help to increase the profit in your organisation?
ii. Cost implications of implementing Six Sigma (e.g. training, hiring new staff etc.).
iii. The importance of Kano Analysis and other Six Sigma tools (with example).
iv. How FMEA can help to reduce risks and variations?

Write a draft Board Paper for your boss based on the above key points. Use examples and diagrams when necessary.


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