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-6. -4. -2. 0. 2. 4. 6. Improving Processes - Exercises. Identifying Solutions. Identifying Solutions. Identifying Solutions. Possible Solutions?. Identifying Solutions. Identifying Solutions. NOT ROOT CAUSE. NOT ROOT CAUSE. Identifying Solutions. Cost/Benefit Analysis.

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Improving Processes - Exercises




Identifying solutions2
Identifying Solutions

Possible Solutions?



Identifying solutions4
Identifying Solutions

NOT ROOT CAUSE

NOT ROOT CAUSE



Cost benefit analysis
Cost/Benefit Analysis

  • You are considering buying a new Ford Escape

  • The Escape is available with two power plants:

    • Standard Gasoline Engine ($21,000, 24 mpg - city)

    • Hybrid-Gas/Electric Engine ($27,000, 36 mpg - city)

  • The average price of gas is $2.35/gallon.

  • Without considering the cost of money or differences in maintenance expenses, how long would it take to pay-back the higher initial cost of the car through improved gas mileage?


Evaluating solutions
Evaluating Solutions

  • Develop a Countermeasure Matrix for the following potential solutions:

Problem

Root Causes

Potential Solutions

Exercise More

High BMI

Eat Healthy Foods

High Blood

Pressure

Reduce Alcohol Consumption

Change Job

High Job Stress

Work Less on Current Job

Reduce Calorie Consumption


Barriers aids
Barriers & Aids

  • For the countermeasures of “eat healthy food” & “exercise more often” develop a barriers & aids analysis:

Current State:

High Blood Pressure

Future State:

Low Blood Pressure


Solution fmea
Solution FMEA

  • The Engineering Scheduling process was modified as follows:

  • What could go wrong with the process changes?


Changing
Changing

  • Part 1 – Recall a change that was successful in your company. Why was it successful? What factors contributed to it’s success?

  • Part 2 - Recall a change that was not successful in your company. Why was it not successful? What factors contributed to it’s not being a success?


Change

Leading Change

CurrentState

Making Change Last

Creating A Shared Need

ImprovedState

Shaping A Vision

Monitoring Progress

Mobilizing Commitment

TransitionState

Changing Systems & Structures

Change

  • Suppose your company management decided that “Six Sigma” was needed to drive necessary improvements in processes and competitiveness.

  • Apply the elements of change to help them build a “plan” for introducing and implementing Six Sigma:


Change1
Change

  • Thinking about the “Six Sigma Plan” you just developed, profile your company’s Change Processes:


Pin wheel design
Pin Wheel Design

We’ll use a simple product – a pinwheel – to help apply & tie together Process Control Planning:

CTQs

Pinwheel

Design



Pinwheel fabrication assembly process
Pinwheel Fabrication & Assembly Process

  • Process Steps

  • Cut dowel rod to length (16”) (Supplier)

  • Print pinwheel pattern (Supplier)

  • Cut out pinwheel pattern

  • Punch holes in pinwheel

  • Cut slits in pinwheel

  • Bend paper clip to pattern

  • Tape paper clip to dowel

  • Insert back button

  • Insert center of pinwheel on paper clip

  • Bend pinwheel wings and insert holes on paper clip (clockwise order)

  • Insert front button

  • Bend over tip of paper clip to secure button

  • Materials:

  • Pinwheel pattern printed

  • Dowel rods (48”)

  • Paper Clips (large)

  • Shirt Buttons

  • Tape

  • Tools:

  • Scissors

  • Hole Punch

  • Needle-Nose Pliers

  • Ruler


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