Project

Note: This template has been modified from its original version retrieved from:

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PROCESS IMPROVEMENT PLAN

COMPANY NAME

STREET ADDRESS

CITY, STATE ZIP CODE

PREPARED BY:

DATE

http://www.projectmanagementdocs.com/project-planning-templates/process-improvement-plan.html

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TABLE OF CONTENTS

INTRODUCTION ……………………………………………………………………………………………………………….. 2
PROCESS BOUNDARIES ……………………………………………………………………………………………………… 2
PROCESS CONFIGURATION ………………………………………………………………………………………………… 3

PROCESS METRICS …………………………………………………………………………………………………………… 4
TARGETS FOR IMPROVED PERFORMANCE…………………………………………………………………………….. 5

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INTRODUCTION

The CAX Cable project was initiated by BTS Tech in order to develop a new coaxial cable

product capable of delivering high-definition picture and sound quality for residential use. This

project includes the development of the cable product as well as the manufacturing process

required to produce the product. The CAX Cable process improvement plan describes how the

manufacturing processes will be analyzed in order to continually monitor and improve

production efforts. The process improvement plan will be followed iteratively throughout the

project’s lifecycle and includes all processes involved with the manufacturing of the CAX Cable.

The process improvement plan lays out the necessary steps to identify, measure, and implement

the necessary process improvements for the CAX Cable product.

PROCESS BOUNDARIES

The CAX Cable Project consists of two processes which comprise the overall manufacturing

process: cable stranding and cable jacketing. Cable stranding consists of the stranding of the

internal metallic cable element with protective Kevlar fibers in order to improve cable tensile

strength. Cable jacketing consists of jacketing the stranded core with an extruded polyethylene

cover in order to protect the internal cable structure from environmental effects and ensure the

transmission of data signals. As part of the process improvement plan the stranding and

jacketing process boundaries have been established below:

Stranding:

 Start – the stranding process starts immediately upon an order being placed for

material from the operations manager

 Completion – the stranding process is complete once the stranded core (of pre-

determined length) has been built and spooled on a cable reel and moved to the

holding area

 Inputs – the inputs for the stranding process are: core length (based on order),

materials, written work order, and user defined inputs on the stranding machine

 Outputs – the outputs for the stranding process are: a stranded core on a cable reel (of

pre-determined length), and an acknowledged work authorization from the stranding

machine technician

 Data Required – the data required for the stranding process is: total cable length,

finished cable diameter, and core material types

 Process Owner – the stranding process owner is J. Green, Senior Process Technology

Engineer

Jacketing:

 Start – the jacketing process starts immediately upon receipt of a stranded cable core

from the receiving area.

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 Completion – the jacketing process is complete once the stranded core is jacketed,

spooled on a cable reel, and sent to the finished cable holding area

 Inputs – the inputs for the jacketing process are: a stranded cable core and an

acknowledged work authorization from the stranding machine technician (which

includes all jacketing material specifications)

 Outputs – the outputs of the jacketing process are: a jacketed (completed) CAX Cable

with a specification chart and acknowledged work authorization from the jacketing

line technician

 Data Required – the data required for the jacketing process is: extrusion temperature,

cooling trough temperature, material specifications, total cable length, finished cable

diameter, and jacket print specifications

 Process Owner – the jacketing process owner is B. White, Process Technology

Engineer

PROCESS CONFIGURATION

BTS Tech has modeled its initial CAX Cable manufacturing processes on existing processes

currently is use for other cable products and families. The process improvement plan for this

project provides BTS Tech with an opportunity to analyze and improve the cable manufacturing

process for CAX Cable which, ultimately, may result in process improvements for all BTS Tech

cable products. The project team will utilize the stranding and jacketing process configurations,

in conjunction with process metrics, to conduct process analyses, determine potential areas for

improvement, and implement improvement measures. To do this, the team will follow the

processes as planned during initial cable runs in order to verify process boundaries and gather

metrics. As the team identifies potential process areas of improvement, adjustments will be

made and the modified process will be run to validate the process and to gather additional

metrics for comparison.

Stranding Process Configuration:

Inputs:

Core Length

Materials

Written Work Order

User Defined Inputs

Stranding Line

Technician loads

materials and enters user

defined inputs

Technician runs line to

build stranded cable

core

Stranded core is

spooled and moved to

holding area

Technician awaits delivery of

material from stockroom

while preparing stranding

machine

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Jacketing Process Configuration:

PROCESS METRICS

Process metrics and control limits will be used, in conjunction with process configuration, to

guide the process improvement efforts for the CAX Cable project. Since the stranding and

jacketing processes for CAX Cable are based on the processes for other cable families, the

metrics, acceptable values, and control limits are known. However, as part of the CAX Cable

process improvement plan, the project team will iteratively analyze the process configurations,

metrics, and measured values in order to implement a cycle of continuous improvement. The

existing metrics, values, and control limits are based on industry-wide customer requirements for

cost and performance.

Stranding:

Metric
Acceptable Mean

Value
Upper Control Limit Lower Control Limit

Core material waste 7% 9% 5%

Stranding time per
linear km

35 minutes 40 minutes 32 minutes

Time from material
ordered to line

ready
45 minutes 55 minutes 40 minutes

Inputs:

Stranded cable core

Acknowledged work

order

Technician sets jacketing

machine parameters and

print settings

Technician runs line to

build jacketed cable

Completed cable is

spooled and moved to

holding area

Technician loads stranded

core and prepares jacketing

machine for cable run

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Jacketing:

Metric
Acceptable Mean

Value
Upper Control Limit Lower Control Limit

Jacketed cable
waste

9% 13% 7%

Jacketing time per
linear km

40 minutes 46 minutes 37 minutes

Time from receipt
of stranded core to

line ready
26 minutes 32 minutes 23 minutes

Measurements for each metric will be taken for every iteration of a stranding and jacketing for a

trial CAX Cable. These measurements will be plotted on a control chart in order to ensure that

process parameters fall within the acceptable range. As the process is validated for this new

product and the values normalize, the project team will use the metrics and process

configurations to determine areas within the processes where improvements can be made. As

adjustments to the processes are made, the team will continue to track the metrics in order to

validate any improvements to the process and for updates or changes to project documentation.

TARGETS FOR IMPROVED PERFORMANCE

The CAX Cable project team has developed targets for improved performance in each of the

metrics for both the stranding and jacketing processes. These metrics are based on existing BTS

Tech metrics for all other cable products and families. However, this project provides an

opportunity to improve these processes which may potentially result in significant savings for

cost and time for CAX Cable as well as all other BTS Tech cable products. The charts below

provide the CAX Cable stranding and jacketing process metrics with both the current values and

target values.

Stranding:

Metric
Current or

Target Values
Acceptable
Mean Value

Upper Control
Limit

Lower Control
Limit

Core Material
Waste

Current 7% 9% 5%

Target 5% 7% 3%

Stranding time
per linear km

Current 35 minutes 40 minutes 32 minutes

Target 32 minutes 37 minutes 29 minutes

Time from
material ordered

to line ready

Current 45 minutes 55 minutes 40 minutes

Target 42 minutes 50 minutes 38 minutes

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Jacketing:

Metric
Current or

Target Values
Acceptable
Mean Value

Upper Control
Limit

Lower Control
Limit

Jacketed cable
waste

Current 9% 13% 7%

Target 7% 10% 5%

Jacketing time per
linear km

Current 40 minutes 46 minutes 37 minutes

Target 35 minutes 40 minutes 32 minutes

Time from receipt
of stranded core

to line ready

Current 26 minutes 32 minutes 23 minutes

Target 22 minutes 27 minutes 19 minutes

Based on current capacity of BTS Tech cable products, the targeted stranding and jacketing

waste reductions will result in over $550,000 in material savings annually. The stranding and

jacketing process time targets will allow the operations group to increase throughput and achieve

significant increases in scheduling flexibility which will allow BTS Tech to better meet its

customer requirements.

SPONSOR ACCEPTANCE

Approved by the Project Sponsor:

__________________________________________ Date: ___________________

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