FINANCE DEPARTMENT
PROJECT: BACKROOM
Sony Six Sigma
Champion: Marcelo Freitas
Black Belt: Joao Franco
Green Belt: Mauro Perin and
Andre Belleza
Ver.2.4
DEFINE PHASE
Sony Six Sigma
Ver.2.4
Customer Diagram
Date: 02/SEP/03
Company/Plant
COSTS OPTIMIZATION AND
CONTROL
HOME OFFICE
COLUMBIA
TRISTAR
Department/Title
FINANCE &
ADMINISTRATIVE
DIRECTOR
Name
MARCELO
FREITAS
Ver.2.4
Define Diagram
2. Commitment to Your
Process
Department FINANCE DIRECTOR
Name MARCELO FREITAS
Date 02/SEP/ 03
Commitment (in plain
language understandable to
the customer)
1. Customer and VOC
Customer
HOME OFFICE
 Customer Requirements with Voice
FREIGHT COSTS REDUCTION
BACKROOM COSTS REDUCTION
 Basic Requirements without Voice
REDUCTION IN 30% OF
THE FREIGHT AND
BACKROOM COSTS BY
THE END OF THE FY04
(FEBRUARY/04)
CASH FLOW IMPROVEMENTS
COMPLIANCE WITH LEGAL REQUIREMENTS
 Subconscious Expectation
ELIMINATE AUDIT ISSUES
VOC
FREIGHT AND BACKROOM COSTS
REDUCTION IN 30%
Ver.2.4
CE Diagram
Department: Finance Director, Columbia Tristar
Name: Marcelo Freitas Date: 02/SEP/03
Promote
economy of
scale
Create Prints
Destruction
Policy
Achieve Freight single
supplier.
Present
Freight &
Backroom cost
until Sep/03 was
R$ 1,8 million
Optimize
Backroom Cost
Destroy used
Prints
Customer
Home Office
VOC
TRANSPORTATION &
STORAGE COSTS
REDUCTION
Commitment
REDUCTION IN
30% OF THE
FREIGHT AND
BACKROOM
COST.
Improve Skills
Train
Personnel
Ver.2.4
CTQ Diagram - A
Department:
Name:
What
FINANCE DIRECTOR, COLUMBIA TRISTAR
M.FREITAS
Date: 02/SEP/03
To What Extent
When to achieve
Person In
Charge
CTQ1
Achieve Freight Single
Supplier
100%
End of FY04
Franco
CTQ2
Optimize Backroom Cost
30%
End of FY04
Franco
CTQ3
Destroy Used Prints
70%
End of FY04
A. Sala
CTQ4
Improve Skills
100% of Personnel
End of FY04
A. Sala
CTQ5
CTQ6
CTQ7
CTQ8
Ver.2.4
BACKROOM EXPENSE (R$ 000)
300
250
200
150
100
50
0
2000
2001
2002
Setima Arte
CEF Repres
RP
MURUNDU
2003*
SDF
*Data collected until August
Ver.2.4
BACKROOM LOCATION
CEF Repres
(MG)
10%
SDF (SP)
32%
Setima Arte
(PE)
19%
RP (RS)
14%
MURUNDU
(RJ)
25%
Setima Arte (PE)
CEF Repres (MG)
RP (RS)
MURUNDU (RJ)
SDF (SP)
Ver.2.4
PRINT UNITS DELIVERED (2002)
BACKROOMS
8.000
7.000
6.804
6.000
5.537
5.000
4.000
3.542
3.000
2.744
2.149
2.000
1.000
SDF (SP)
MURUNDÚ
(RJ)
CEF (MG)
SETIMA
ARTE (PE)
RP (RS)
Ver.2.4
Tree Diagram
Improvement Target:
Optimize Backroom
Cost
Reduce in 30% the
Backroom cost in SP
Reduce 30%
Backroom cost
OTHER STATES
Ver.2.4
MEASURE PHASE
Sony Six Sigma
Ver.2.4
Process Flow Diagram
Start
Labs duplicate
Prints and send
to the Backrooms
Transport
Co.A
Murundu informs
Sales about the
Prints.
SDF informs
Sales about the
Prints.
Sales instructs
Backroom to send
the Print to the
Theatres
Sales instructs
Backroom to send
the Print to the
Theatres
Transport
Co.B
Transport
Co.C
Transport
Co.D
Transport
Co.E
Transport
Co.F
THEATRES
Ver.2.4
INVOICE BREAKDOWN
Department: Finance Director, Columbia Tristar
Name: Marcelo Freitas Date: 14
/OCT
/03
BREAKDOWN OF THE STORAGE COST ON THE INVOICE
9.000
8.000
7.000
6.000
5.000
4.000
3.000
2.000
1.000
0
January
February
March
Movimentaçao de kit promocional
Armazenagem de filme
Entrada de filme
Saída de filme
Prateleiras ocupadas
April
May
June
July
August
Seguro advalorem
Armazenagem de trailer
Entrada de trailer
Saída de trailer
Iss
Ver.2.4
INVOICE BREAKDOWN
INVOICE BREAKDOWN
9%
5%
8%
3%
6%
24%
11%
8%
13%
Movimentaçao Kit
Armazenagem Trailer
Saída Filme
Iss
S. Advalorem
Entrada Filme
Saída Trailer
13%
Armazenagem Filme
Entrada Trailer
Prateleiras
Ver.2.4
Tree Diagram
Metric
Improvement Target
Optimize
Backroom
Cost
Reduce in 30%
the Backroom
cost in SP
Reduce Storage
cost of Films.
OTHER STATES
Other Costs
on the invoice
Percentage
of Storage
Cost on
the Invoice
Reduce
30%
Backroom
cost
Ver.2.4
Project Purchase Order Sheet (PPO)
FINANCE
CH Name: MARCELO FREITAS
Date: 14 /OCT/03
BB Name: FRANCO
Dept.:
STEP-2/14
STEP-2/14
CTQ
STEP-3/14
Project Name
What to achieve
Optimize Backroom Costs
BACKROOM
To what extent
Improvement
Metrics
Percentage of Storage
Cost on Invoice
STEP-5/14
Current
Values
24% of Total Invoice
relates to Storage Cost.
30%
When to achieve
End of FY04 (February/04)
STEP-5/14
CH Approval Date 02
CH Signature
STEP-5/14
Marcelo Freitas
STEP-5/14
PGS
Schedule
02/09/03
Measure
14/10/03
Analyze
14/11/03
-)
Improve
14/12/03
PGS
Control
14/01/04
R$ 300 K annual
Investment:
Target
Values
Reduce from 24% to
17% the Storage Cost
STEP-5/14
Define
Gains+Savings:
/SEP/03
Project Members
GB Mauro Perin
Andre Belleza
Ver.2.4
ANALYSE PHASE
Sony Six Sigma
Ver.2.4
CE Diagram
Department: Finance, Columbia Tristar
Name: Mauro Perin
Date: 14/OCT/03
Ver.2.4