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7 Step Improvement Process. Tumolo’s Toolbox. Elements of process improvement and control. Every process has three (3) elements 1. The area of discovery Understanding the customer requirements and developing the process to meet these requirements

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Tumolo s toolbox

7 Step Improvement Process

Tumolo’s Toolbox


Elements of process improvement and control

Elements of process improvement and control

Every process has three (3) elements

1. The area of discovery

Understanding the customer requirements and

developing the process to meet these requirements

2. The method of process control

Assessing performance and variation

3. The element of improvement

Problem solving and quality improvement


Tumolo s toolbox

Process Improvement Opportunity or Problem Identification

7 Step Improvement Process

Process Control


Tumolo s toolbox

the in

innovation

insight

invention

inspiration

intuition

instinct

prayer

clairvoyance

Copy

Imitation

consultation

Benchmark

Other world

Inner self

Improvement

or Problem

others

delegation

negotiation

just waiting

passing-the-buck

confusing

finger pointing

transferring

real world

gut feel

systematic

PDCA

7 Steps

random

trial-and-error

guess

accident

chance

luck


Tumolo s toolbox

7 QC Tools

PDCA

7 STEP

Check sheet, graph,

Histogram, scatter diagram,

Pareto diagram,

cause-and-effect diagram,

flowcharts

Flowcharts

Check sheet, graph,

Histogram, scatter diagram,

Pareto diagram,

cause-and-effect diagram,

run chart/control chart

Flowchart

1. Select a Theme

2. Collect Data

3. Analyze causes/opportunities

4. Plan and implement

solution / improvement

5. Evaluate effects

6. Standardize

7. Reflect on process

PLAN

DO

CHECK

ACT

(provides repetition) (provides process) (provides tools)


Tumolo s toolbox

7 Step improvement process

  • Focus on weakness

  • Thoroughly explore the problem/opportunity

  • Carefully select the theme

  • Clearly state the theme

  • Have weakness orientation

  • State as a problem/gaps, not a solution

  • State in terms of results

1. Select Theme

2. Collect Data

3. Analyze Causes

4. Plan Solution and Implement

5. Evaluate

6. Standardize

7. Reflect on Process


Tumolo s toolbox

Selecting the theme

  • Weakness is difference between current situation and the target.

  • Weakness orientation focuses on eliminating weakness as basis

  • of improvement (Closing the Gap).

}

}

Customer

Need

Current

Weakness

Weakness

Actual

Performance

Target

Focus on facts, processes, and root causes


Tumolo s toolbox

7 Step improvement process

  • Define your data collection process

    • Appropriate to process

    • Multi-variable data

  • Analyze the data

    • Stratification

    • Graphics

    • Focus on deviation

  • Draw a logical conclusion

    • Based on facts

    • Focus on vital few

1. Select Theme

2. Collect Data

3. Analyze Causes

4. Plan Solution and Implement

5. Evaluate

6. Standardize

7. Reflect on Process

“Primary tool used is Pareto Diagram


Tumolo s toolbox

Frequently used data collection tools

Used to systematically collect data or tabulate data.

(e.g. frequency of occurrence of defect types)

Excellent method to identify vital few. (2 levels minimum)

(e.g. Percent of failures due to various defect types

arranged in descending order of occurrence)

Method to identify non-standard process variation

(e.g. Solder paste height versus time)

Method to identify trends in data

(e.g. In circuit test yield versus time)

Method to identify distribution of the data

(e.g. Number or solder paste observations falling into

various height ranges)

CHECKSHEET

PARETO DIAGRAM

CONTROL CHART

GRAPH (RUN CHART)

HISTOGRAM


Tumolo s toolbox

7 Step improvement process

  • Create cause-and-effect

  • diagram from Pareto

  • Investigate cause thoroughly

  • Draw logical conclusions

  • (i.e. supported by data)

1. Select Theme

2. Collect Data

3. Analyze Causes

4. Plan Solution and Implement

5. Evaluate

6. Standardize

7. Reflect on Process

Ask Why?5 times


Tumolo s toolbox

100%

2nd why

4th why

Methods

Material

Pareto

Diagram

5th why

3rd why

1st why

A

Man

Machine

Cause effect

Diagram

A B C D E F

  • ASK 5 WHYS to get to the proper level of analysis and causes.

  • Segment by 4 Ms

    • Man

    • Machine

    • Methods

    • Material


Tumolo s toolbox

Verifying Root Causes

Collect data on root causes

Use run charts, Pareto, Graphs, scattergrams, etc. to determine strength of correlation between root cause and problem

If verification fails to validate choices, return to diagram and choose new root causes to verify.


Tumolo s toolbox

7 Step improvement process

  • Focus on the primary root causes

  • Focus on solution which you can

  • implement

  • Dont try to fix everything at once

  • Involve those who will be affected

  • Run a controlled experiment (Pilot)

1. Select Theme

2. Collect Data

3. Analyze Causes

4. Plan Solution and Implement

5. Evaluate

6. Standardize

7. Reflect on Process


Tumolo s toolbox

= LOW

= HIGH

= MEDIUM

Solectron Criteria

Feasibility

Effectiveness

Total Score

A tool to help determine which

solution is best.

Solution 1

Solution 2

Solution 3

Solution 4

-------

Scoring values

Possible score 3 or 2 or 1

values 6 3


Tumolo s toolbox

A tool to help determine ease or

difficulty in solving specific

problems.

Area of Problem

Equipment Methods Human

Behavior

You

You and

Others

Others

Easy Easy Difficult

Data Collection/

Potential solution

implementation

Moderately Moderately Very

Difficult Difficult Difficult

Very

Difficult Difficult Difficult


Tumolo s toolbox

Solution Implementation

WhatWhenWhereWhoHow

How will they get it done

Who is responsible for doing it

Where will it be done

When will it be done

What will be done


Tumolo s toolbox

7 Step improvement process

  • Confirm improvement

  • (Before and after comparison)

  • Evaluate all subsequent effects

  • Measure improvement gains over

  • time

1. Select Theme

2. Collect Data

3. Analyze Causes

4. Plan Solution and Implement

5. Evaluate

6. Standardize

7. Reflect on Process


Tumolo s toolbox

}

Original Pareto

“BEFORE

Improvement

New Pareto

“AFTER

100%

}

Pareto

Diagram

Effect on

Root Cause

“Fewer defects

A B C D E F


Tumolo s toolbox

7 Step improvement process

  • Move from PDCA to SDCA cycle

  • Revise the standard

  • Create a process to detect future

  • problems

1. Select Theme

2. Collect Data

3. Analyze Causes

4. Plan Solution and Implement

5. Evaluate

6. Standardize

7. Reflect on Process


Tumolo s toolbox

Standardization

PDCA

SDCA

New

Std

Do

Std

Do

Plan

Act

Act

Check

Check

Control

Improvement


Tumolo s toolbox

7 Step improvement process

  • Analyze strengths and weaknesses

  • Determine the next problem

  • Document the Quality improvement

  • story

  • Identify the critical difficulties during

  • the process - using tools, etc.

  • Identify the critical strengths

  • Identify the key things the team

  • would do differently

  • Identify what key things the team

  • needs to learn to improve the 7 step

  • process.

1. Select Theme

2. Collect Data

3. Analyze Causes

4. Plan Solution and Implement

5. Evaluate

6. Standardize

7. Reflect on Process


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