MP-001 Process Discovery.pptx

SIX SIGMA BLACK BELT MEASURE PHASE  INTRODUCTION This course has been designed to build your knowledge and capability to improve the performance of processes and subsequently the performance of the business of which you are a part. The focus of the course is process centric. Your role in process...

SIX SIGMA BLACK BELT MEASURE PHASE  INTRODUCTION This course has been designed to build your knowledge and capability to improve the performance of processes and subsequently the performance of the business of which you are a part. The focus of the course is process centric. Your role in process performance improvement is to be through the use of the methodologies of Six Sigma, Lean and Process Management. By taking this course you will have a well rounded and firm grasp of many of the tools of these methodologies. We firmly believe this is one of the most effective classes you will ever take and it is our commitment to assure that this is the case. MEASURE PHASE Process Discovery  OVERVIEW OF BRAINSTORMING TECHNIQUES A commonly used tool to solicit ideas by using categories to stimulate cause and effect relationship with a problem. It uses verbal inputs in a team environment.  CAUSE AND EFFECT DIAGRAM A commonly used tool to solicit ideas by using categories to stimulate cause and effect relationship with a problem. It uses verbal inputs in a team environment. Products Categories for the legs of the Transactional –Measuremen –People diagram can use templates for t –Policy –People products or transactional –Procedure –Method symptoms. Or you can select the –Place –Materials categories by process step or –Measureme –Equipment what you deem appropriate for nt –Environment the situation. –Environmen t  CAUSE AND EFFECT DIAGRAM The Measurement category groups causes related to the measurement and measuring of a process activity or output: Examples of questions to ask: Is there a metric issue? Measurement Is there a valid measurement system? Is the data good enough? Is data readily available? Y The People category groups root causes related to people, staffing, and organizations: Examples of questions to ask: People Are people trained, do they have the right skills? Is there person to person Y variation? Are people over- worked?  CAUSE AND EFFECT DIAGRAM The Method category groups root causes related to how the work is done, the way the process is actually conducted: Examples of questions to ask: Method How is this performed? Are procedures correct? What might unusual? Y The Materials category groups root causes related to parts, supplies, forms or information needed to execute a process: Examples of questions to ask: Are bills of material current? Y Are parts or supplies obsolete? Are there defects in the materials Materials  CAUSE AND EFFECT DIAGRAM The Equipment category groups root causes related to tools used in the process: Examples of questions to ask: Have machines been serviced recently, what is the uptime? Y Have tools been properly maintained? Is there variation? Equipment The Environment (a.k.a. Mother Nature) category groups root causes related to our work environment, market conditions and regulatory issues. Examples of questions to ask: Is the workplace safe and comfortable? Y Are outside regulations impacting the business? Does the company culture aid the process? Environment  CLASSIFYING THE X’S The Cause & Effect Diagram is simply a tool to generate opinions about possible causes for defects. For each of the X’s identified in the Fishbone diagram classify them as follows: Controllable – C (Knowledge) Procedural – P (People, Systems) Noise – N (External or Uncontrollable) Think of procedural as a subset of controllable. Unfortunately, many procedures within a company are not well controlled and can cause the defect level to go up. The classification methodology is used to separate the X’s so they can be used in the X-Y Matrix and the FMEA taught later in this module. WHICH X’s CAUSE DEFECTS? 9  CHEMICAL PURITY EXAMPLE Measurement Manpower Materials Incoming QC (P) Training on method (P) Raw Materials (C) Measurement Insufficient staff (C) Method (P) Skill Level (P) Multiple Vendors (C) Measurement Capability (C) Adherence to procedure (P) Specifications (C) Work order variability (N) Chemical Startup inspection (P) Room Humidity (N) Column Capability (C) Purity Handling (P) RM Supply in Market (N) Nozzle type (C) Purification Method (P) Shipping Methods (C) Temp controller (C) Data collection/feedback (P) Methods Mother Nature Equipment  CAUSE & EFFECT DIAGRAM - MINITAB™ Below is a Cause & Effect Diagram for surface flaws. The next few slides will demonstrate how to create it in MINITAB™.  CAUSE & EFFECT DIAGRAM - MINITAB™ Open the MINITAB™ Project “Measure Data Set.mpx” and select the worksheet “Surface flaws.”. 12 CAUSE & EFFECT DIAGRAM - MINITAB™  CAUSE & EFFECT DIAGRAM - MINITAB™ In order to adjust the Fishbone Diagram so the main causes titles are not rolled grab the line with your mouse and move the entire bone.  15 THANK FOR YOUR ATTENTION!!! YOU