DMAIC Project Assignment Report: Optimizing Wet Cake Storage at SK Biotek’s P3 Plant

Problem Statement

The primary objective of this project is to ensure adequate and compliant storage solutions for wet cake storage in the P3 Plant at SK Biotek. Due to the increased production from the B-154 campaign, which started in November 2024 and will continue until February 2025, the current storage area has proven insufficient. Furthermore, parallel processing of B-172 starting in late November 2024 will exacerbate the storage issue. After reviewing potential solutions, the preferred approach is to procure ATEX-rated mobile storage containers to accommodate the additional batches.

Project Goals

The goals of this project include:

• Ensuring sufficient storage capacity to accommodate increased production.
• Maintaining compliance with safety and regulatory standards.
• Reducing storage-related delays and inefficiencies.
• Implementing a cost-effective and sustainable storage solution.

SIPOC Diagram

Voice of the Customer (VOC) Analysis

To ensure that the proposed solution meets the expectations and requirements of stakeholders, a Voice of the Customer (VOC) analysis was conducted. The following sources were used to gather customer feedback:

• Surveys and interviews with operations, quality, and engineering teams.
• Feedback from regulatory compliance officers.
• Input from senior management regarding production efficiency and cost-effectiveness.
• Direct observations of storage practices and challenges.
• Analysis of historical production and compliance reports.

Customer Needs and Expectations

Conclusion

The Define phase of the DMAIC project establishes the foundation for the wet cake storage optimization at SK Biotek. Through the SIPOC diagram and VOC analysis, key stakeholders’ needs and expectations were identified, guiding the project’s direction. The next steps involve measuring current inefficiencies and analyzing improvement opportunities to ensure a sustainable and compliant solution.

Measure Phase

Introduction

The Measure phase focuses on collecting data to quantify the current storage inefficiencies in the P3 Plant at SK Biotek. This phase involves establishing key performance metrics, analyzing baseline data, and ensuring that measurement systems are reliable and accurate.

Key Performance Metrics

To assess the current situation and establish baseline performance, the following key metrics were identified:

• Time taken for batch storage allocation.
• Frequency of storage shortages or delays.
• Impact on overall production efficiency.
• Compliance with safety and regulatory standards.
• Timeline tracking for container procurement and deployment.

Baseline Data Collection

The following dummy data was collected over a one-month period to analyze current storage performance:

Measurement System Analysis (MSA)

To ensure the reliability of the collected data, a Measurement System Analysis (MSA) was performed. This analysis included evaluating repeatability, reproducibility, and consistency of the measurement system.

Pareto Analysis

A Pareto analysis was conducted to determine the primary causes of storage inefficiencies. The analysis revealed that:

• 40% of delays were due to unavailability of storage space.
• 30% of delays were caused by slow approval processes.
• 20% of delays resulted from temperature control issues.
• 10% were due to miscommunication between departments.

Conclusion

The Measure phase established a clear understanding of the current state of wet cake storage efficiency in the P3 Plant. The data collected highlights key bottlenecks and inefficiencies, which will be further analyzed in the next phase to determine the root causes and develop strategies for improvement. The Measurement System Analysis (MSA) validated the reliability of the data collection process, ensuring that any process changes are based on accurate measurements.

Analyze Phase

Introduction

The Analyze phase focuses on identifying the root causes of inefficiencies in the wet cake storage process at SK Biotek. Using data collected in the Measure phase, various analytical tools were applied to determine key issues affecting storage performance.

Root Cause Analysis

A Root Cause Analysis (RCA) was performed to systematically identify the major causes contributing to storage inefficiencies. The RCA included the use of Fishbone Diagrams, 5 Whys, and Failure Modes and Effects Analysis (FMEA).

Fishbone Diagram Analysis

The Fishbone Diagram (Ishikawa) helped categorize root causes under various factors such as manpower, methods, materials, machinery, environment, and measurement. The key findings were:

• Manpower: Lack of adequate personnel trained in optimized storage methods.
• Methods: Inefficient workflow in batch storage allocation.
• Materials: Insufficient ATEX-rated storage units leading to compliance risks.
• Machinery: Inadequate temperature control mechanisms in existing storage.
• Environment: External environmental factors affecting storage conditions.
• Measurement: Inconsistent tracking of storage allocation time and delays.

5 Whys Analysis

A 5 Whys Analysis was conducted to determine why storage inefficiencies were occurring. An example from the storage shortage issue is detailed below:

1. Why are there storage shortages? → Increased production volume
2. Why has production volume increased? → B-154 campaign requirements
3. Why weren’t storage needs anticipated? → Inadequate forecasting process
4. Why is forecasting inadequate? → Lack of cross-departmental coordination
5. Why is there no coordination? → No formal process for production-storage planning

Failure Modes and Effects Analysis (FMEA)

Conclusion

The Analyze phase identified key root causes contributing to storage inefficiencies in the P3 Plant. Using Root Cause Analysis, Fishbone Diagrams, 5 Whys, and FMEA, critical issues were diagnosed. The findings from this phase will be used to develop targeted improvement strategies in the next phase.